Re: radiator replacement on 87 5000 CST

[Aleksander Mierzwa <alex@matrix.pl>]

At 16:38 13.08.98 EDT, JamieC5361@aol.com wrote:

>I have purchased an all metal radiator & hoses for my 87 5000 CST. I am an
>extreme amatuer, so I  need to know where the bolt is to drain the cooling
>system. Also any other tips on this procedure would be very helpful.

There's no drain plug, you just remove the lower radiator hose and let the
coolant drain. 

1. Disconnect the negative lead from the battery. Remove the upper plastic
radiator shroud.
2. Slacken the hydraulic pump's mounting and adjustment locking nuts.
Release the drivebelt tension by turning the adjusting bolt ani-clockwise.
Remove the drivebelt.
3. Remove three bolts holding the hydraulic pump bracket to the head. Move
the hydraulic pump as far to the left (assuming you're standing in front of
the car) as the hydrualic lines allow. Usually it is possible to put the
pump on the valve cover. Secure the pump in this position with a wire, duct
tape or whatever. 
4. Remove the coolant expansion tank cap. Put a (preferably large)
container under the car and remove the lower radiator hose. The coolant
will drain. If you want to replace all the coolant, you also need to remove
the hose that goes from the rear of the engine to the heater (it is usually
a PITA to remove). Otherwise leave it alone.
5. Remove the upper radiator hose. Remove the coolant expansion tank. 
6. Disconnect the temp sensor connector at the bottom at the radiator.
Disconnect the wires from the radiator fan.
7. Crawling under the car, remove several 10mm bolts securing the lower
plastic shroud to the radiator. Then remove the 13mm nut securing the lower
radiator mount to the body. It is reported that some newer cars have two
lower mounts. My '87 5KT has only one, but check this on your car.
8. Remove the 10mm bolts and nuts securing the radiator to it's upper
mounts and to the A/C condenser.
10. The A/C condenser is hooked to the radiator at the bottom. Holding it
with both hands, pull it upwards, then pull it towards yourself to unhook
it from the metal tab at the bottom of the radiator.
11. The radiator should be removed with the shroud and fan motor attached.
Swivel the radiator to your right, then remove it by pulling diagonally to
the left and upwards.

While the radiator is out, you should consider doing some preventive
maintenace while you are at it. Replacing the thermostat never hurts and
the access to it is very good while the radiator is out. Another good idea
is to remove the fan motor and take it to a good electrician, particularly
if it's been making some grinding noises lately. Most fan motor on Audis of
this vintage have worn bearings. The fan motor is not fused, so should a
bearing seize, it results in melted wiring harness. It is almost impossible
to remove the fan motor without removing the radiator, so now it's a good
moment to take care of this. Beware: the nut securing the fan to the motor
has a LEFT-HAND THREAD. 

Refitting is a reverseal of removal, as expensive manuals say.

Aleksander Mierzwa
Warsaw, Poland
mailto:alex@matrix.com.pl
87 Audi 5000CS turbo (mine)
88 Renault Medallion wagon (mom's)
91 mountain bike (just in case both cars broke at the same time :-)