Contents: Extraction ↓ Radiator installation ↓
Extraction
1. Disconnect the negative battery cable.
2. Drain the liquid from the cooling system.
3. Disconnect the electrical wire from the thermal switch and from the radiator fan motor (photo 2.3 and 2.4) and disconnect the upper hose from the radiator (photo 2.5).
5. Disconnect the air outlet pipe from the fitting 2 of the equalizing tank (photo 2.1).
6. Remove the two bolts securing the radiator to the front area (photo 2.6, 2.7 and 2.8).
The bolt in the middle of the upper plane of the front zone secures the radiator bracket. After unscrewing this bolt, we remove the bracket by moving it upwards. The right side of the radiator is then released. The left side of the radiator is screwed with a bolt through a rubber-metal bushing. It is enough to unscrew the bolt to also release the left side.
7. Remove the plastic radiator cover 4 (see figure 11.1).
8. Unscrew the four fastening bolts, left and right air guides 1 and 6 (figure 2.2) from the sides of the radiator.
Figure 2.2. Cooling system - 1.1 and 1.3 l engines
1 - left cover; 2 - bolt securing the radiator; 2a - permanent mounting bracket; 3 - pressure belt; 4 - head/radiator pipe; 5 - radiator; 5a - fastening bolt; 5b - removable bracket, 6 - right cover. 7 fan blades 8 - fan motor, 9 - fan cover; 9a - fastening the wires supplying the fan; 10 - expansion tank pipe/heater pipe; 11 - radiator thermal switch; 12 - expansion tank. 13 - expansion tank/radiator pipe; 14 - cork; 15 - outlet fitting.
9. Remove the radiator from the engine chamber, being careful not to damage it (photo 2.9). If necessary, you can unscrew the four upper bolts that secure the front part to the wings and bend this part slightly.
10. Unscrew the screws and remove the casing together with the fan from the radiator (photo 2.10).
11. Repairing a radiator is impossible without special equipment, although small leaks can be sealed with a sealing agent.
12. Clean the radiator tubes from insects and small leaves with a soft brush or water from a hose. Then flush the radiator in the opposite direction as described in point 5. Replace the hoses and clamps if they are damaged or torn.
Radiator installation
13. Installation is performed in the reverse order of removal. During installation, it is necessary to replace the shock absorber rubber on the lower bolts securing the radiator (photo 2.11). The radiator fixing bolts must be inserted into the corresponding holes in the cross beam.
14. Insert the central bracket into the radiator socket (photo 2.8) and press it down. Insert and tighten the second bolt securing the radiator (photo 2.6).
15. Fill the cooling system with liquid.
16. Connect the radiator fan motor wires and secure them to the 9A rib (figure 2.2) fan shroud.
(The original article is available on the website: vwmanual.ru)
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