1999 Volkswagen Jetta radiator and AC cooling

Radiator, removing and installing
Fig. 128: Identifying Special Tools - Radiator, Removing And Installing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Drip pan VAG 1306 for Shop crane VAG 1202 A
Torque wrench (5-50 Nm) or equivalent VAG 1331 or equivalent
Hose clip pliers VAG 1921
Hydrometer
Main radiator
Auxiliary radiator

Removing

Drain coolant, refer to Coolant, draining and filling.
Remove front bumper: Refer to FRONT BUMPER
Pull quick-coupler off radiator.
Disconnect connectors from thermal switch and coolant fans.
Place lock carrier into service position: Refer to LOCK CARRIER SERVICE POSITION
Remove radiator retaining screws and remove radiator and fan from below.
NOTE: For vehicles with air conditioning.

Installing

Installation is in reverse order, but note the following:

Fill with coolant, refer to Coolant, draining and filling.
Notes and assembly procedures for vehicles with air conditioning
CAUTION: Do not open the A/C refrigerant circuit.

NOTE: To prevent damage to the condenser, refrigerant lines and hoses, be careful that the lines and hoses are not overstretched, creased or bent.

Unscrew retention strap(s) on refrigerant lines.
Remove condenser from radiator and fasten to lock carrier.
Auxiliary radiator
Removing

Drain coolant, refer to Coolant, draining and filling.
Remove right front sound-proofing mat: Refer to NOISE INSULATION (GASOLINE ENGINES), ASSEMBLY OVERVIEW or NOISE INSULATION (DIESEL ENGINES), ASSEMBLY OVERVIEW
Remove fender liner, front right: Refer to 66 EXTERIOR EQUIPMENT
Remove front right air outlet: Refer to 63 BUMPER
Remove windshield washer reservoir: Refer to 92 WINDSHIELD WIPER & WASHER SYSTEM
Fig. 129: Locating Coolant Hoses At Auxiliary Radiator In Engine Compartment Below Right Headlight
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using pliers for spring band clips ( Hose Clip Pliers VAG 1921 ), pull coolant hoses off auxiliary radiator in engine compartment below right headlight - arrows -.
Fig. 130: Locating Coolant Hoses At Auxiliary Radiator In Engine Compartment Below Right Headlight
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove upper retaining screws - 1 - of auxiliary cooler.
Remove lower retaining screws in front wheel housing from bracket.
Carefully remove auxiliary radiator with its attachments from below.
Installing

Installation is in reverse sequence, but observe the following directions:

Fill with coolant refer to Coolant, draining and filling.