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    1989 Honda Prelude 2.0L FI 4cyl

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    Volkswagen Cars 2000-05

    Removal & Installation

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    CAUTION
    NEVER open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

    1. Disconnect the negative battery cable.
    2.  
    3. Allow the engine to cool below 100°F (38°C).
    4.  
    5. Drain the coolant into a suitable container. For additional information, please refer to the following topic(s): General Information and Maintenance, Fluids and Lubricants.
    6.  
    7. On A4 & 1998-00 Passat models, remove the front bumper assembly. For additional information, please refer to the following topic(s): Body and Trim, Front Bumper.
    8.  
    9. Remove the radiator hoses from the radiator.
    10.  
    11. Disconnect the electrical connectors for the thermal fan switch and the electric cooling fan.
    12.  
    13. On models equipped with automatic transmission, if equipped, place a suitable drain pan under the fluid lines, then disconnected and plug the transmission cooling lines.
    14.  
    15. On 1990-97 Passat models:
    16.  
      1. Remove the radiator mounting fasteners.
      2.  
      3. Remove the upper radiator support/hood lock carrier. Outline the mounting fasteners for proper assembly.
      4.  
      5. Carefully lift out the radiator complete with the fan assembly.
      6.  

    17. On A4 & 1998-00 Passat models:
    18.  
      1. Remove the mounting fasteners for the power steering cooling lines and move aside without disconnecting.
      2.  
      3. If equipped with air conditioning:
      4.  
      5. Remove the left and right side air guides.
      6.  
      7. Remove the A/C condenser retaining clamp fasteners and retaining clamp.
      8.  
      9. Disconnect the A/C pressure switch just beneath the headlamp.
      10.  
      11. Place a suitable protective cover over the right fender, then move the condenser upward away from the retaining bracket and pivot to the side and support it at the right front wheel area using a sturdy wire loop or its equivalent. Do NOT disconnect the A/C lines from the condenser and avoid severe bending and kinking.
      12.  
      13. Release the upper radiator retaining bolts, pulling up and removing.
      14.  
      15. Tilt the radiator forward, lifting up to remove.
      16.  




    Click image to see an enlarged view

    Fig. On A4 & 1998-00 Passat models, the upper radiator fasteners are removed by releasing the retaining bolts, then pulling up to remove

    To install :

    1. Installation is in reverse order of removal noting the following points:
    2.  
    3. Fill and bleed the cooling system with the recommended fluid and mixture ratio. The recommended engine coolant should only be diluted with distilled water. For additional information, please refer to the following topic(s): General Information and Maintenance, Fluids and Lubricants.
    4.  

    1. Drain the coolant into a suitable container.
    2.  
    3. Remove the bumper cover, as follows:
      1. Remove the radiator grille and expanding clips (connecting elements between bumper cover and wheel housing).
      2.  
      3. Remove the spray nozzles of headlight cleaning system (if equipped).
      4.  
      5. Remove the 8 bolts.
      6.  
      7. Disconnect air ducts from bumper cover.
      8.  
      9. Disconnect harness connectors.
      10.  
      11. Push down the retaining tab at left/right using a screwdriver and pull bumper cover parallel out of side guides.

        Click image to see an enlarged view

        Fig. Push down the retaining tab (arrow) at left/right using a screwdriver and pull bumper cover parallel out of side guides

      12.  

    4.  
    5. Remove the front bumper, refer to the accompanying illustration.

      Click image to see an enlarged view

      Fig. Exploded view of the front bumper cover, bumper and related components

    6.  
    7. Disconnect the coolant hoses from radiator.
    8.  
    9. Disconnect the harness connectors from Coolant Fan Control (FC) thermal switch and coolant fan.
    10.  
    11. Remove the headlights:
      1. Remove the mounting screws, then pull the headlight housing out slightly toward the front of the vehicle.
      2.  
      3. Detach the headlight multi-pin harness connector.
      4.  
      5. Pull the headlight housing out toward front of the vehicle..
      6.  

    12.  
    13. For vehicles without A/C, remove both radiator mounting bolts and remove radiator toward the front of the vehicle.
      WARNING
      Do not disconnect the A/C refrigerant lines! To avoid damaging the condenser and refrigerant lines/hoses, do NOT stretch or allow them to kink.

    14.  
    15. For vehicle with A/C:
      1. Remove the air cleaner.
      2.  
      3. Remove both radiator mounting bolts.
      4.  
      5. Remove retaining clamps from A/C refrigerant lines.
      6.  
      7. Separate condenser from radiator and pull it forward as far as possible.
      8.  
      9. Remove radiator between condenser and lock carrier (radiator support).

        Click image to see an enlarged view

        Fig. Exploded view of the radiator, fan and related components

      10.  

    16.  

    To install:

    1. Installation is the reverse of the removal procedure, noting the following:
      1. Fill the cooling system with the proper type and amount of coolant.
      2.  
      3. Adjust the headlights, as follows:

        Click image to see an enlarged view

        Fig. View of the left headlight (adjusting screws of right headlight are a mirror image)-1: lateral adjustment, 2: vertical adjustment

      4.  
      5. To adjust the lateral and height setting of the headlight, turn respective adjusting wheel using a screwdriver.
        NOTE
        Adjusting headlight adjusts fog light and high beam simultaneously.



        Click image to see an enlarged view

        Fig. To adjust the lateral and height setting of the headlight, turn respective adjusting wheel using a screwdriver

      6.  

    2.  


    NOTE
    This procedure requires the following special tools equipment, or their equivalents:



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

    1. Drain the coolant into a suitable container.
    2.  
    3. Detach the electrical connectors from the thermal switch (1) and coolant fan (2).

      Click image to see an enlarged view

      Fig. Detach the electrical connectors from the thermal switch (1) and coolant fan (2)

    4.  
    5. For all models except R32 Golf, remove front bumper cover, as follows (refer to the illustration):
      1. Remove the release lever locking clamp upward.
      2.  
      3. Spread the release lever- using a screwdriver, then remove from lid lock.
      4.  
      5. Remove release lever with guide from the lock carrier.
      6.  
      7. Remove the radiator grille.
      8.  
      9. If equipped, remove covers (7) for headlight cleaning system from bumper cover and unclip.
      10.  
      11. Remove the bolts (5) securing the bumper cover (1) to the wheelhousing (4).
      12.  
      13. Unclip the left air guide grille (9) and right air guide grille (11).
      14.  
      15. Remove the bolts connecting the bumper cover (1) to the sound insulation on left and front underbody.
      16.  
      17. Remove the bolts (2).
      18.  
      19. Remove bumper cover (1) from guide pieces (3) (left and right).
      20.  
      21. Disconnect connector from temperature sensor.
      22.  
      23. Remove spoiler (8) if necessary

        Click image to see an enlarged view

        Fig. Bumper cover removal and installation-except Golf R32

      24.  

    6.  
    7. For the R32 Golf, remove the front bumper cover, as follows (refer to the illustration):
      1. Remove the release lever locking clamp upward.
      2.  
      3. Spread the release lever- using a screwdriver, then remove from lid lock.
      4.  
      5. Remove release lever with guide from the lock carrier.
      6.  
      7. Remove the radiator grille.
      8.  
      9. Pull off covers (9) for headlight cleaning system from bumper cover and unclip.
      10.  
      11. Loosen bumper cover (1) in area of wheelhousing (4).
      12.  
      13. Unclip left ventilation grid (10) and right ventilation grid (12).
      14.  
      15. Remove bolts (2). Remove the bumper cover (1) from guide pieces (3) (left and right sides).
      16.  
      17. Disconnect harness connector from temperature sensor.

        Click image to see an enlarged view

        Fig. Bumper cover removal and installation-Golf R32

      18.  

    8.  
    9. Bring lock carrier into service position, as follows:
      1. Disconnect Bowden cable at the lock.
      2.  
      3. Remove one bolt each at longmembers and screw in Guide rods 3411 at right and left longmembers for this.
      4.  
      5. Remove bolts and pull lock carrier toward front in area of Guide rods 3411 .

        Click image to see an enlarged view

        Fig. Position the lock carrier into the service position using the guide rods

      6.  

    10.  
    11. Pull coolant hoses quick release couplings off radiator.
    12.  
    13. Remove securing screws for headlight and disconnect connections
    14.  
    15. If equipped with A/C, perform the following:
      1. Unfasten the 4 A/C condenser mounting bolts.

        Click image to see an enlarged view

        Fig. Unfasten the 4 A/C condenser mounting bolts

      2.  
      3. Remove the bolt (arrow) on left of radiator for condenser bracket.

        Click image to see an enlarged view

        Fig. Remove the bolt (arrow) on left of radiator for condenser bracket

      4.  

    16.  
    17. For vehicles without A/C, unfasten the radiator mounting bolts, remove the radiator with fan from the vehicle, by sliding it downward.
      WARNING
      Do NOT disconnect any A/C refrigerant lines!


      NOTE
      To prevent damage to the condenser as well as to the refrigerant lines, ensure that lines and hoses are not stretched, kinked or bent.



      Click image to see an enlarged view

      Fig. Unfasten the radiator mounting bolts, remove the radiator with fan from the vehicle, by sliding it downward

    18.  
    19. If equipped with A/C, perform the following:
      1. Remove retaining clamp(s) from refrigerant lines.
      2.  
      3. Remover radiator securing bolts from side of radiator.
      4.  
      5. Remove condenser from radiator.
      6.  
      7. Secure condenser to body, so that refrigerant lines/hoses are not under stress.
      8.  
      9. Swing radiator out downward and remove it.
      10.  

    20.  

    To install:

    1. Installation is the reverse of the removal procedure, noting the following:
      1. Make sure the electrical connections are properly connected and routed.
      2.  
      3. Fill the engine with the proper type and amount of coolant.
      4.  

    2.  


    NOTE
    This procedure requires the following special tools equipment, or their equivalents:



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

    1. Drain the coolant into a suitable container.
    2.  
    3. Remove the front bumper. Refer to the accompanying illustration.

      Click image to see an enlarged view

      Fig. Exploded view of the front bumper-New Beetle

    4.  
    5. Disconnect the coolant hoses from the radiator.
    6.  
    7. Disconnect connectors from thermal switch and coolant fan.
    8.  
    9. Remove the lock carrier.
    10.  
    11. If not equipped with A/C, remove the radiator mounting bolts, then remove the radiator from the vehicle.
      WARNING
      Do NOT disconnect any A/C refrigerant lines!


      NOTE
      To prevent damage to the condenser as well as to the refrigerant lines, ensure that lines and hoses are not stretched, kinked or bent.

    12.  
    13. If equipped with A/C, perform the following:
      1. Remove retaining clamp(s) from refrigerant lines.
      2.  
      3. Remover radiator securing bolts from side of radiator.
      4.  
      5. Remove condenser from radiator.
      6.  
      7. Secure condenser to body, so that refrigerant lines/hoses are not under stress.
      8.  
      9. Swing radiator out downward and remove it.
      10.  

    14.  

    To install:

    1. Installation is the reverse of the removal procedure, noting the following:
      1. Make sure the electrical connections are properly connected and routed.
      2.  
      3. Fill the engine with the proper type and amount of coolant.
      4.  

    2.  

    1.8L And 2.0L Engines




    NOTE
    This procedure requires the following special tools equipment, or their equivalents:



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

    1. Drain the coolant into a suitable container.
      NOTE
      Refer to the accompanying illustrations for bumper removal details.

    2.  
    3. For vehicles manufactured through 9/00, remove the front bumper cover, as follows:
      1. Remove the turn signal.
      2.  
      3. Remove the release lever (15) from the hood latch.
      4.  
      5. Unfasten bolts (9, 10 and 14).
      6.  
      7. Remove the bumper cover (1) from the guide pieces (4 - left and right sides) parallel, with the help of an assistant.
      8.  
      9. Detach the harness connectors for all installed electrical components and hoses.

        Click image to see an enlarged view

        Fig. Exploded view of the front bumper cover-Passat models manufactured through 9/00

      10.  

    4.  
    5. For vehicles manufactured after 10/00, remove the front bumper cover, as follows:
      1. Remove the radiator grille.
      2.  
      3. Unfasten the upper bolts (2).
      4.  
      5. Remove the quick-release screw (6) from underneath.
      6.  
      7. Remove the bolts (5 and 4 - pointing upward) in area of wheel housing liner.
      8.  
      9. With the help of an assistant, pull the cover parallel out of guides.
      10.  
      11. Detach the harness connectors for all installed electrical components and hoses.

        Click image to see an enlarged view

        Fig. Exploded view of the front bumper cover-Passat models manufactured 10/00 and after

      12.  

    6.  
    7. Disconnect the coolant hoses from radiator.
    8.  
    9. Detach the harness connector from thermal switch.
    10.  
    11. If equipped with an automatic transaxle, disconnect the ATF lines from radiator
    12.  
    13. Remove the cooling coil for power steering fluid (arrows) and allow it to hang free; Do not disconnect the fluid lines.

      Click image to see an enlarged view

      Fig. Remove the cooling coil for power steering fluid (arrows) and allow it to hang free; Do not disconnect the fluid lines.

    14.  
    15. For vehicles without A/C, remove the upper radiator securing clips and remove radiator toward front.
      WARNING
      Do not disconnect the A/C refrigerant lines!

    16.  
    17. If equipped A/C, perform the following:
      NOTE
      Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.

      1. Remove retaining clamp(s) for refrigerant lines.
      2.  
      3. Remove condenser from radiator and pull forward as far as possible.
      4.  
      5. Secure condenser to body so that the refrigerant lines/hoses are not burdened.
      6.  
      7. Pull the radiator out, maneuvering it between the condenser and lock carrier.
      8.  

    18.  

    To install:

    1. Installation is the reverse of the removal procedure, noting the following:
      1. Check ATF level, if equipped with an automatic transaxle
      2.  
      3. Fill the engine with the proper type and amount of coolant.
      4.  
      5. Make sure all harness connectors are routed properly.
      6.  
      7. Install the front bumper cover.
      8.  
      9. Check headlights and adjust if necessary.
      10.  

    2.  

    2.8L And 4.0L Engines



    1. Remove the sound insulator
      NOTE
      Refer to the accompanying illustrations for bumper removal details.

    2.  
    3. For vehicles manufactured through 9/00, remove the front bumper cover, as follows:
      1. Remove the turn signal.
      2.  
      3. Remove the release lever (15) from the hood latch.
      4.  
      5. Unfasten bolts (9, 10 and 14).
      6.  
      7. Remove the bumper cover (1) from the guide pieces (4 - left and right sides) parallel, with the help of an assistant.
      8.  
      9. Detach the harness connectors for all installed electrical components and hoses.

        Click image to see an enlarged view

        Fig. Exploded view of the front bumper cover-Passat models manufactured through 9/00

      10.  

    4.  
    5. For vehicles manufactured after 10/00, remove the front bumper cover, as follows:
      1. Remove the radiator grille.
      2.  
      3. Unfasten the upper bolts (2).
      4.  
      5. Remove the quick-release screw (6) from underneath.
      6.  
      7. Remove the bolts (5 and 4 - pointing upward) in area of wheel housing liner.
      8.  
      9. With the help of an assistant, pull the cover parallel out of guides.
      10.  
      11. Detach the harness connectors for all installed electrical components and hoses.

        Click image to see an enlarged view

        Fig. Exploded view of the front bumper cover-Passat models manufactured 10/00 and after

      12.  

    6.  
    7. Drain the coolant into a suitable container.
    8.  
    9. Remove quick release couplings of coolant hoses from radiator.
    10.  
    11. Disconnect harness connector from thermal switch.
    12.  
    13. If equipped with an automatic transaxle, disconnect the ATF lines from radiator
    14.  
    15. Remove the cooling coil for power steering fluid (arrows) and allow it to hang free; Do not disconnect the fluid lines.

      Click image to see an enlarged view

      Fig. Remove the cooling coil for power steering fluid (arrows) and allow it to hang free; Do not disconnect the fluid lines.

    16.  
    17. For vehicles without A/C, remove the upper radiator securing clips and remove radiator toward front of the vehicle.
      WARNING
      Do not disconnect the A/C refrigerant lines!

    18.  
    19. If equipped A/C, perform the following:
      NOTE
      Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.

      1. Remove retaining clamp(s) for refrigerant lines.
      2.  
      3. Remove condenser from radiator and pull forward as far as possible.
      4.  
      5. Secure condenser to body so that the refrigerant lines/hoses are not burdened.
      6.  
      7. Pull the radiator out, maneuvering it between the condenser and lock carrier.
      8.  

    20.  

     
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