Removing and installing radiator, Polo: VW 1.6 TDI (CAYA, CAYB, CAYC, CHZB, …)

🧭 Before you start

The access work is the bulk of it: drain the coolant, remove the front bumper cover and the radiator cowl. Then detach the top hoses, unbolt the radiator, tilt it back and lift it off the lower mountings, tie the condenser into the bonnet lock latch and unclip the charge air cooler's water radiator so both radiators can come out. Going back together: new O-rings, hose clips engaged with release tool VAS 531 001, condenser and cowl refitted, bumper cover on, and the system filled with fresh coolant.

Fits: VW Polo 6C (2014–2017)

• Opens: coolant
• Renewed: o-rings
• Also covered elsewhere: Installing coolers, condensers and radiators

Don't miss

• Drain the coolant first and do not put the old coolant back in; refill with fresh.
• Hose clips (1 and 2) at the top left are not ordinary clips; engage them with release tool VAS 531 001.
• Hang the condenser in the bonnet lock latch with cable ties; it must not drop on its pipes.
• Unclip the charge air cooler's water radiator from the main radiator before lifting both out.
• Renew the O-rings and check the fins for dents before the radiator goes back in.
• Bleed the cooling system after refilling and check the level again once the engine has reached temperature.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📋 Procedure

1. Drain coolant Draining and filling coolant.
2. Remove bumper cover General body repairs, exterior63Front bumper; Removing and installing bumper cover.
3. Remove radiator cowl Removing and installing radiator cowl.
4. Detach coolant hoses on top left of radiator. To do this, loosen hose clips (1 and 2) using hose clip pliersVAS 6362.
5. Remove bolts (arrows).

6. Tilt top of radiator slightly backwards.
7. Raise radiator, disengage from lower mounting points and push backwards.
8. Remove bolts (arrows).
9. Place condenser in bonnet lock latch at front and secure with cable ties to prevent it from falling.
10. Release catches on water radiator for charge air cooler (1)(arrows A).
11. Pull water radiator for charge air cooler off radiator (2)(arrow B), and detach it (arrow C).
12. Remove both radiators. [Note: If there are minor dents in the fins, refer to Installing coolers, condensers and radiators.Renew O-rings.] [Note: The design of the clips (1 and 2) is different from that of conventional clips and requires a special tool for the clips to be engaged.]
13. Push coolant hoses with hose clips (1 and 2) onto radiator at top.
14. Engage clips (1) in direction of (arrow) using release toolVAS 531 001.
15. Vehicles with air conditioning system: Install condenser Heating, air conditioning system87Refrigerant circuit; Removing and installing condenser.
16. Install radiator cowl Removing and installing radiator cowl.
17. Install front bumper cover General body repairs, exterior63Front bumper; Assembly overview - bumper cover. [Note: Do not reuse old coolant.]
18. Replenish coolant Draining and filling coolant.

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