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    1978 Volkswagen Truck Transporter 2.0L FI 4cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    Pacifica, 2003-2005

    Removal & Installation

    Print

    1. Disconnect negative cable from battery.
    2.  
    3. Discharge the A/C system, as outlined in the Heating & Air Conditioning section.
    4.  
    5. Remove the front fascia, as follows:
      1. Release hood latch and open hood.
      2.  
      3. Remove the headlamp assemblies.
      4.  
      5. Hoist vehicle and support with safety stands, as necessary.
      6.  
      7. Remove the four screws attaching bottom of fascia/air dam to radiator closure panel.
        NOTE
        The whole front splash shield does not need to be removed.

      8.  
      9. Remove three screws attaching front fascia to front splash shield on each side.
      10.  
      11. Remove the screw attaching fascia to the front fenders on each side .
      12.  
      13. Disconnect fog lamp wire connectors, if necessary.
      14.  
      15. Lower vehicle.
      16.  
      17. Remove push pins attaching the upper appearance panel to upper crossmember.
      18.  
      19. Remove screw attaching the upper grille support to the headlamp mounting panel at each side of the grille.
      20.  
      21. Remove bumper fascia from vehicle.
      22.  
      23. Place fascia on a clean surface.

        Click image to see an enlarged view

        Fig. View of the upper and lower front fascia and related components

        View of the upper and lower front fascia and related components
      24.  
      25. Remove spring clips attaching upper and lower fascia together.
      26.  
      27. Using a trim stick release locking tabs and separate the upper and lower fascia.
      28.  
      29. Remove the bright chrome molding from the upper fascia. Using a trim stick, starting at the outer edge of the fascia release the locking tabs. Grip the molding and pull outward from the fascia while releasing the locking tabs.
      30.  
      31. Remove molding from fascia.
      32.  
      33. Remove grille from fascia.
        CAUTION
        Do not remove the cylinder block plug or the radiator draincock with the system hot and under pressure because serious burns from coolant can occur.

      34.  

    6.  
    7. Drain the cooling system.
    8.  
    9. Disconnect the radiator fan electrical connectors.
    10.  
    11. Disconnect coolant reserve/recovery hose.
    12.  
    13. Remove A/C lines.
    14.  
    15. Remove the auxiliary transmission cooler hoses.
    16.  
    17. Remove the pushpins and the upper radiator seal.
    18.  
    19. Remove the pushpins and the LH and RH radiator seal.
    20.  
    21. Remove the A/C condenser side brackets to radiator attaching screws. Separate the condenser from the radiator by lifting upward to disengage from lower mounts. Allow the condenser to rest in front of radiator.
    22.  
    23. Remove the upper and lower radiator hoses.
    24.  
    25. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.
    26.  
    27. Remove the auxiliary transmission from the radiator module.
    28.  
    29. Remove the cooling fan assembly from the radiator module.

      Click image to see an enlarged view

      Fig. Exploded view of the radiator module (1), auxiliary transaxle cooler hoses (2) and cooler (3)

      Exploded view of the radiator module (1), auxiliary transaxle cooler hoses (2) and cooler (3)
    30.  

    To install:

    1. Install A/C condenser, (if removed).
    2.  
    3. Install radiator fan assemble, if removed.
    4.  
    5. Install auxiliary transmission cooler, if removed.
    6.  
    7. Slide radiator down into position. Seat the radiator with the rubber isolators into the mounting holes provided, with a 10 lbs. force.
    8.  
    9. Install mounting screws.
    10.  
    11. Connect the cooling fan electrical connector.
    12.  
    13. Install the radiator upper and lower hoses
    14.  
    15. In the LH and RH radiator seals.
    16.  
    17. Install the upper radiator seal.
    18.  
    19. Install the auxiliary transmission cooler hoses.
    20.  
    21. Connect the coolant reserve/recovery hose.
    22.  
    23. Install the front fascia, as follows:
      1. Place bright chrome molding in position on the upper fascia.
      2.  
      3. Using hand presser press bright chrome molding locking tabs in the full lock position.
      4.  
      5. Position upper and lower fascia on a clean surface so that locking tabs align with the slots.
      6.  
      7. Press the fascia together to lock locking tabs into position.
      8.  
      9. Install new spring clips attaching upper and lower fascia together. The spring clips are not reusable.
      10.  
      11. Place bumper fascia into position on vehicle.
      12.  
      13. Install grille to fascia.
      14.  
      15. Install screw attaching the upper grille support to the headlamp mounting panel at each side of the grille.
      16.  
      17. Install push pins attaching the upper appearance panel to upper crossmember.
      18.  
      19. Raise vehicle and support with safety stands, as necessary.
      20.  
      21. Connect fog lamp wire connectors, if necessary.
      22.  
      23. Position and align fascia slotted cut out into fender push fastener.
      24.  
      25. Install screw attaching fascia to the front fenders on each side.
      26.  
      27. Install front wheelhouse splash shields fasteners as necessary.
      28.  
      29. Install front wheels.
      30.  
      31. Install the four screws attaching bottom of fascia/air dam to radiator closure panel.
      32.  
      33. Lower vehicle.
      34.  
      35. Install the headlamp assemblies.
      36.  
      37. Close hood.
      38.  

    24.  
    25. Fill the cooling system.
    26.  
    27. Connect negative cable to battery.
    28.  

     
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