Before removing the old radiator, obtain a replacement plus a couple of hose retaining clips. These are a dealer only part:
Drive the car onto ramps and remove the front undershield. It's held in place under the car by five quarter-turn fasteners and one nut. Plus four plastic quarter-turn fasteners, two under each wheel arch.
Detach the bonnet release t-bar through the aperture circled in red. Insert a screwdriver in the forked end of the lever to release it from the mechanism. Remove the two fasteners circled in green. Remove the grille by releasing the clip on the top (to the right of the release lever) and the four at the bottom. The bottom clips can be released by pulling the grille forward and reaching down the back.
To remove the bumper, first undo four fasteners from the top.
Then remove the four screws from under each wheel arch. Slide the bumper forward and remove from the vehicle.
Remove the plastic bumper support by removing the five fasteners indicated.
Remove the steel bumper by removing the nut and three fasteners on each side.
Remove the two fasteners indicated in red and move the pipework away from the condensor. Undo the two fasteners indicated in yellow and remove the two side shields.
Unclip the electrical connector circled in purple. Remove the four fasteners circled in green.
Lift away the condensor and support temporarily. The radiator can now be drained if necessary using the tap on the bottom right hand side (as viewed). Remove the two plastic retainers (arrowed) from the top of the radiator.
Remove the retaining clips from the upper...
...and lower hoses using a screwdriver. The lower hose is best accessed from under the car. Pull the hoses off the radiator - this can take some effort.
The radiator can now be removed. If an aftermarket universal-type radiator is being fitted, remove the bosses indicated using a hacksaw. Remember to transfer the rubber mountings across from the old radiator before disposing of it.
Refitting is the reverse of removal.
passat vw 2003 tdi 1.9
ReplyDeletecould you also do this forpassat vw 2003 tdi 1.9
ReplyDelete?
yeah same car, mine is a 2003
DeleteWhat size sockets/torx bits do you need to remove the steel bumper ?
ReplyDeleteThis comment has been removed by the author.
Delete8mm torx socket
DeleteHow about a passat 2000
ReplyDeleteWell done excellent
ReplyDeleteIt is a very nice information about Volkswagen Passat car.If anybody needs to Buy Volkswagen Passat Tyres Online please visit Tyreonwheels.
ReplyDeleteThe car's a piece of garbage never designed it should be shot hung and beat the hell out of town should have made just a regular hose I like to kill a cock sucking on them in a plastic radiator
DeleteThe car's a piece of garbage never designed it should be shot hung and beat the hell out of town should have made just a regular hose I like to kill a cock sucking on them in a plastic radiator
DeleteMaybe because you don't know how to work on them, one of the best cars ever made
DeleteThank you!
ReplyDeleteThanks for the write up Tony!
ReplyDeleteChanged the rad on my Passat on Saturday. I have a few tips that might help future DIYers.
1. Ordered the clips from ebay (part no 1J0121142), but they did not arrive in time. Bottom one was shot, top one was usable. Swapped the top to the bottom, and improvised the top one with some galvanized gardening wire wound round the hose and twisted with pliers. Clips arrived on Tuesday morning and I snipped off the wire and installed the new clip without loosing any coolant. Lower one will be replaced at a later date.
2. I missed some off the steps. I didn't jack the car or remove the undertray, and I didn't remove the pipework at the bottom right of the radiator (bolts were badly corroded and I was worried that they would shear). New rad was a little difficult to get in with the pipework in place, but by removing the bleed screw and pulling the pipework a little it went in.
3. Lower hose clip was hard to access from the top. I got the screwdriver on the top side of it and it broke leaving most of the clip in place (again corroded). I really did not want to take the undertray off so I pulled the rad out a bit and hack-sawed off the lower connection. Then with the rad out of the way I could move the hose end and get access remove the remains of the clip. With the clip gone the amputated lower connection end was removed using a pair of pliers.
4. The new rad (EIS brand from Eurocarparts) has clipnuts for the upper condenser retainers, instead of plastic bosses like the VW original so the screws cant be re-used. I used 4x M6x12 bolts to attach the condenser retainers. M6x15 would work fine too.
Hope this helps, thanks again!
Hi, I am looking @ buying this rad and using this blog to fit, its currently £38 delivered from EUROPARTS. Have you had any problems with the radiator since fitting in 2016 ?
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Hi, I need to also replace the fan on the engine, its plastic housing broke and destroyed the radiator. Any tips ?
ReplyDeleteFollowed this step by step instruction and fixed my car, £60 all in with all parts, thanks to the blogger for this.
ReplyDeleteJust for anyone want to do this, the so called original VW Radiator that failed that even had VW stamped on top had a small sticker on the side revealing who really made it, its made by NISSENS so dont get fooled into thinking that you should buy a new one direct from VW, they dont make the radiator, NISSEN make it, manufacturer link here :
ReplyDeletehttps://nissens.com/en-gb/automotive/radiators.aspx