Removing and installing radiator with charge air cooler (Polo)

Assembly overview - parts of cooling system, body side ⇒ 3.3 Assembly overview - radiator/radiator fan (Polo).

Special tools and workshop equipment required

• Hose clamp pliers - VAS 6340-
• Torque wrench (5 … 50 Nm) - V.A.G 1331-

Removing

• Drain coolant (Polo) ⇒ 1.6 Draining and filling coolant (Polo).
• Pull upper coolant hose off radiator.
• Removing cowling with both radiator fans ⇒ 3.7 Removing and installing radiator fan - V7- and radiator fan 2 - V177- (Polo).
• Remove both charge air hoses.

• Disconnect electrical connector -arrow-.

• Pull connector -arrow- from radiator outlet coolant temperature sender - G83-.
• Bring lock carrier into service position ⇒ General body repairs, exterior; Rep. gr. 50; Body - front; Lock carrier - service position.

• Remove securing bolts -arrows-.
• Lift radiator out of lower mountings and press it back slightly.
• Remove side radiator mounting.
• Unscrew securing bolt on side for AC compressor lines.

• Remove securing bolts of condenser -arrows-.
• Secure condenser to lock carrier using cable ties.
• Remove radiator and charge air cooler downwards.

• Pull radiator -1- in -direction of arrow- out of lateral charge air cooler -2- mounting brackets.

Installing

Installation is carried out in the reverse order. When installing, note the following:

Filling with new coolant ⇒ 1.6 Draining and filling coolant (Polo).

• Electrical connections and routing ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

Specified torques