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Re: Radiator Coming Out

At 08:38 PM 4/22/98 +0000, you wrote:
>Well, once again I have a project going and am stalled.  Last night, 
>I noticed the passenger side plastic cap on our 1990 200's radiator 
>was leaking....enough to require immediate attention.  Im pretty sure 
>I can get the end cap replaced or re-sealed once I get the unit out.
>So tonight, I went to pull the radiator.  THAT is a pretty good 
>trick!  As is all too frequent, the Bentley has not one word or 
>picture to help.  What a puzzle!!!!!!!!!!!!!
>I got the shroud out OK....and the radiator is loose - BUT - the AC 
>condener is still attached to the front of it, and on the driver's 
>side at the bottom, there's a bracket.  Running through this bracket 
>is what must be an AC coolant line.  I cracked the nut, thinking it 
>was something else...but when it hissed at me, I quickly tightened it 
>again, hoping that I hadn't dumped enough freon to require 
>However, I'm not sure I have any option but to break the connection 
>and dump the freon charge in order to get the radiator out....because 
>of that damn bracket it passes through, and because the condenser 
>appears to be mounted to the radiator in such a way that it can't be 
>separated without removing both.
>My problems/questions:
>1)  Is there any way to separate the AC condenser mounted on the 
>radiator's front from that radiator, or must I remove both?
>#2 follows from #1 - 
>2)  If I can separate the two, can I also pull the radiator without 
>breaking the AC line connection?
>3)  Do I have to take that AC connection apart ANYway?????
>I think I know the answers - (no) (no) and (yes), but I want to hear 
>from someone who has BTDT before I proceed and spend the $100 for a 
>freon recharge.  It seems insane to require the air conditioning 
>line be disconnected in order to remove a radiator, but Audi is 
>entirely capable of requiring it.  I'ave already had to take the 
>hydraulic pump off its bracket and move it out of the way as far as I 
>can without removing its hoses.
>General PITA.  Replies are appreciated, friends.  Gotta get this done 
>Thursday night.

Al - I feel your pain!  Here's a re-post of the procedure I did a month or
so ago on my '90 200tqw...you *don't* have to remove the air conditioning

1.  Remove battery ground
2.  Disconnect fan motor wires and set aside
3.  Detach wire plug from the thermosensor on the engine side of radiator;
tie plug out of way to keep from getting wet.  Remove top plastic radiator
4.  Remove 2 bolts (8mm) connecting radiator to a/c condensor, then lift
condensor out of bottom rail of radiator (it hooks on to an L-shaped strip)
and move forward (this may take a little jiggling and leaning condensor
forward to get done).
5.  Remove 2 rubber mounts for upper radiator
6.  Remove 2 rubber mounts (13mm) at bottom, and 2 bolts (10mm) where
shroud attaches to radiator.  Do this before removing hoses or draining any
coolant, otherwise you'll get a faceful of antifreeze while you're doing
this...BTDT.  You have access to all these bolts without taking off
anything at the bottom of the engine.
7.  Remove overflow tank; check for cracks and replace if necessary;
otherwise put cleaner in it, cover hose outlets, and let it soak to remove
deposits while you're doing the rest of the job.
8.  Undo upper and lower radiator hoses
9.  Notice I did not remove the fan or shroud; I left it attached when I
pulled the radiator
10. Unslacken bolt that tightens hydraulic pump belt, remove it, remove
other pivot bolt that holds it on, and lay pump aside on valve cover (rest
of hoses can stay connected)
11. Carefully pull out radiator while avoiding wires around ABS unit, aux
cooling pump, etc.
12. Swap over fan shroud, fan switch and expansion tank hose to new radiator

Next, to quote from Dave, who had the same problem I did:
>- Now this is where mine got interesting.
>Everyone I talked to said theirs had 1 rubber mount, my 1990 has 2 on the
>When I go to swap the rubber mounts over to the new rad, only 1 rubber mount
>fits in. The hole where the second rubber mount goes was threaded for the
>bolt. Hmmmmm. I had 2 89 200q data points and they both said 1 rubber
mount, but 
>mine had 2. It was the orig audi radiator and had a build  date of 7/89.
This difference 
>is on the fender side of the car.

13.  (My build date was 8/89).  I drilled out the incorrect hole for the
other mount (to about 3/8ths) and put another nut behind it, and screwed
the original rubber mount in.  This eliminated the other attachment point
for the shroud but big deal.
14. As they say, reinstall in reverse order!

I didn't have trouble with the plastic outlet nipple on the aux cooling
pump because it was relatively new.  I re-used all hoses and thermostat,
etc. because they were all new in the last 6 months, but if you haven't I'd
do it all at the same time.

Good luck!...........SLM