Removing and installing radiator and fans: VW (AMV, AQN)

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

T10007 Refractometer
V.A.G 1306 Drip tray
V.A.G 1331 Torque wrench (5...50 Nm)
VAS 5024 Assembly tool for spring-type clips

Removing

Removing insulation tray:

=> General body repairs exterior; Repair group 50; Body front; Noise insulation - assembly overview
General body repairs exterior
Body front
Noise insulation - assembly overview

Vehicles with air conditioner

Remove ribbed belt => Page
13-14
.
Remove power assisted steering vane pump with bracket and secure to body with wire; hoses remain connected.

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and installing vane pump on vehicles with VR6 engine
Running gear
Assembly overview: vane pump, reservoir, hydraulic lines
Removing and installing vane pump on vehicles with VR6 engine

Removing air conditioner compressor:

=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket
Heating, Air conditioning
removing and installing compressor bracket

Warning!
The air conditioning system refrigerant circuit must not be opened.
Observe additional information and removal work => Page
19-24
.

Continuation for all vehicles

Remove radiator grille:

=> General body repairs exterior; Repair group 66; Removing and installing radiator grille
General body repairs exterior
Removing and installing radiator grille

Remove lock carrier securing bolts -1- on left and right.
Remove expansion tank from lock carrier and place to one side.
Fold lock carrier with radiator out forwards -arrow-.

Disconnect power assisted steering hydraulic pipe -1- from radiator -arrows- and lay to side.
Pull connectors off thermo switch and radiator fan.

Note:

Mark connectors before detaching from radiator fan.

Now detach the connectors from radiator fan (V35 and V7).

Drain coolant => Page
19-16
.
Pull coolant hoses off radiator.
Lift radiator out upwards complete with fan cowl and fan.

Installing

Installation is carried out in the reverse order, when doing this note the following:

Install ribbed belt => Page
13-14
.
Filling with coolant => Page
19-16
Electrical connections and routing:

=> Electrical system; Repair group 97
Electrical system

Check headlight adjustment and adjust if necessary:

=> Maintenance booklet

Additional information and removal work on vehicles with air conditioner

Warning!
The air conditioning system refrigerant circuit must not be opened.

Note:

To prevent damage to condenser also to the refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

Remove retaining clamp(s) from refrigerant pipes.
Remove condenser from radiator and pull forward as far as is possible.
Remove radiator upwards.
Secure condenser to body so that refrigerant pipes/hoses are not stressed.