Special tools and workshop equipment required

• Counterhold - T10038-

• Centre guide - T10093-

• Release lever - U30800-

• Torque wrench - V.A.G 1331-

• Release lever - 80 200-

Removing

• Remove bumper cover (front)
• Remove the lower soundproofing of the engine
• Remove the main headlight unit with the lower bracket

Continuation only for vehicles with ventilation control

• Remove ventilation control

Continuation only for vehicles with adaptive cruise control unit - J428-

• Disconnect plug connector -1- and pull fastening off impact bar.
• Remove bolts -arrows-.
• Remove the adaptive cruise control unit - J428- -2- assembly.

Continued for all vehicles

• If fitted, clip out the cover for the Bowden cable coupling.
• Clip out cable -1- and -3- in -the direction of arrow a- from the coupling sleeve -2-.
• Turn cable -3- 90º in the direction of arrow -b-.
• Clip cable -3- out of the socket of cable -1- by turning in the -direction of arrow c-.

• Remove filler necks from washer fluid reservoir, to do this: slide necks in -direction of arrow a- and pull out in -direction of arrow b-.

• Loosen the hose clip -1-, and remove the air intake hose.

Note The configuration of the air supply ducts may vary depending on the engine version.

• Undo the screws -2- from both sides.
• Unclip the retaining clips of the air duct at lock carrier and detach.
• Clip out and disconnect the plug connector -3- of the bonnet contact - F266- switch.

• Remove fuse -1-, press down in -the direction of the arrow and disconnect the connector of the -2- crash sensor.
• Move wiring harness clear on lock carrier.

• Unclip the connectors of the horn -1-.
• Free the clips -arrow- with the lever - 80 200- .

• Undo and remove the plug connector -arrow- of the ambient - G17- temperature sensor.

• Unscrew bolts -1-, -2- and -4-.
• Remove the brace of the lock carrier -3-.
• Hold the bonnet tight with suitable workshop equipment.

• Unscrew the bolts -1- and remove the pedestrian protective strip -2- in -the direction of the arrow-.

• Remove the spread catcher -2- and remove the air ducts for radiators -1-, -3- and -4-.

• Remove the left and right upper fixation of the radiator/intercooler/ condenser unit.

• Swivel the assembly out of the radiator / intermediate cooler / condenser in -direction of arrow a-.
• Raise the assembly, move it in -direction of arrow b- and unclip it from the lower brackets -1-.

Separate the assembly radiator / intermediate cooler from the condenser -1-. To do this press from both sides -arrow a- against the retaining tab of the condenser -1-.

• Move the condenser in -direction of arrow b- to remove it from its brackets.
• Fix the assembly of radiator / intermediate cooler correctly in the engine compartment. There are two options for this:
  • Secure the assembly of radiator / intermediate cooler using the support tool - T10038- in such a manner that the lines are not exposed to tension.
  • Place two support blocks under the assembly from radiator / intermediate cooler.

• Unscrew the bolts -2- and screw in the centring guide - T10093- on both sides at the ends.

• Pull out the centring guide - T10093- using a second technician.
• Fold out the cover of the lock carrier -1- in -the direction of the arrow A-. Ensure that, in the process, neither radiator nor condenser are damaged.
• Take out the cover of the lock carrier -arrow B- upwards as shown in the image.

fitting

Fit in reverse order from removal, remembering the following:

Note If damaged, renew clips.

• Check the spacings.
• Perform basic setting of headlights, if installed.

Continuation only for vehicles with adaptive cruise control unit - J428-

• Calibrate adaptive cruise control.