3.2l - Cooling System - Engine Code(s): Cala (coupe) (as of 11.2007) Audi A5 I

COOLING SYSTEM, DRAINING AND FILLING

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Adapter V.A.G 1274 tester V.A.G 1274/10
3. Hose clamp pliers V.A.G 1921
4. Cooling system charge unit VAS 6096
5. Drip tray for workshop crane VAS 6208
6. Refractometer T10007

Note. Secure all hose connections with hose clamps appropriate for the model. The arrows on the coolant pipes and ends of coolant hoses must align.

DRAINING

Note. Collect escaping coolant in a clean container for disposal or reuse.

Open coolant reservoir cap.

Remove noise insulation by loosening fasteners -1- and -2-.

Scheme 1

Place drip tray VAS 6208 under engine.

Remove drain plug -1- and drain coolant.

Scheme 2

Note. Ignore -2-.

Remove coolant hose -arrow- from oil cooler and let coolant drain.

Scheme 3

FILLING

1. Ignition switched off.

Note. The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water. Only use one of the frost and corrosion additives approved for this vehicle . Other coolant additives may above all reduce the corrosion protection effect significantly. The damage resulting from this may lead to loss of coolant and consequently to severe engine damage. Frost and corrosion protection additives prevent freezing and corrosion damage and scaling. They also raise the boiling point. For this reason the system must be filled all year round with frost and corrosion protection additives. Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates. Freeze protection must be assured to about -25° C (in arctic climatic countries to about -35° C). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%. If increased freeze protection is needed because of the climate, the amount of G12 + can be increased, but only up to 60% (frost protection to about -40 °C), otherwise the freeze protection and cooling effectiveness will be reduced. Only use clean drinking water for mixing coolant. Do not use drained coolant in the following situations: If the radiator, heat exchanger, cylinder head or cylinder head seal or cylinder block were replaced. If the coolant is contaminated. Dirty coolant must not be reused. Use Refractometer T10007 to determine level of freeze protection in coolant system.

Close drain plug -1-.

Note. Ignore -2-.

Install coolant hose on oil cooler -arrow-.

Fill coolant reservoir on VAS 6096 with at least 12 liters of premixed coolant with proper mixture ratio

Scheme 4

1. Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection up to -25° C.
2. Coolant freeze and corrosion protection additive (50%) and water (50%) for freeze protection up to -35° C.
3. Coolant freeze and corrosion protection additive (60%) and water (40%) for freeze protection up to -40° C.

Attach Adapter V.A.G 1274/8 to coolant reservoir.

Install cooling system charge unit VAS 6096 on adapter V.A.G 1274/8.

Place air outlet -1- in a small container -2-.

Note. A small amount of coolant which should be collected is drawn off with the discharged air.

Close valves -A- and -B- by turning lever at a right angle to direction of flow.

Connect hose -3- to compressed air.

1. Pressure: 6 to 10 bar pressure.

Open valve -B- by turning level in direction of flow.

Scheme 5

1. The suction jet pump generates pressure in coolant system; indicator on display instrument must move into green area.

Briefly open valve -A- by turning lever in direction of flow so that hose on VAS 6096 coolant reservoir fills with coolant.

Close valve -A- again.

Leave valve -B- open another 2 minutes.

1. More pressure is generated in the coolant system by the suction jet pump; indicator on display instrument must stay in green area.

Close valve -B-.

1. Needle in display must remain in green region, then vacuum in cooling system is sufficient for subsequent filling.

Note. If needle stands below the green area, repeat procedure. If pressure falls, check coolant system for leaks.

Remove pressurized air hose.

Open valve -A-.

1. Coolant is extracted from VAS 6096 coolant reservoir by pressure in the coolant system and the system is filled.

Remove cooling system charge unit VAS 6096 form adapter V.A.G 1274/8 on coolant reservoir.

Connect tube V.A.G 1274/10 to adapter V.A.G 1274/8.

Scheme 6

Unclip plenum chamber cover -2- and remove it.

Scheme 7

Note. Ignore -1 and 3- and the -arrow-.

Loosen coolant hose to heat exchanger and pull it back until bleeder hole -arrow- in coolant hose is no longer covered by connection.

Scheme 8

Fill coolant until it escapes from coolant hose bleeder hole.

Slide coolant hose onto connection and secure with a spring clamp.

If vehicle has an auxiliary heater, switch it on for about 30 seconds.

Close coolant reservoir cap.

Start engine.

Adjust temperature for all zones to "HI".

Switch A/C compressor off by pressing ECON button.

Run engine at 2000 RPM for 3 minutes.

Run engine at idle until both large coolant hoses on radiator are warm.

Run engine at 2000 RPM for 1 minute.

Turn off engine and allow it to cool off.

Install front noise insulation, refer to Description and Operation .

Scheme 9

1. With cold engine, coolant level must be at MAX marking.
2. Coolant level may be above MAX marking with engine at operating temperature.

COOLANT HOSE CONNECTION DIAGRAM

Without Auxiliary Heater

Scheme 10

1. Radiator Removing and installing, refer to «RADIATOR»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__radiator) . Change coolant after replacing
2. Coolant pump Removing and installing, refer to «COOLANT PUMP»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__coolant-pump) .
3. Engine Coolant Temperature (ECT) sensor -G62- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .
4. Coolant thermostat Removing and installing, refer to «THERMOSTAT»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) . Checking, refer to «THERMOSTAT, CHECKING»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__thermostat-checking) .
5. Coolant pump -V50- Activated by recirculation pump relay -J160- Removing and installing, refer to «COOLANT PUMP»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__coolant-pump) .
6. Cylinder head and cylinder block Change coolant after replacing
7. Climatronic refrigerant shut-off valve -N422- Removing and installing, refer to «Description and Operation»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2)
8. Bleeder hole
9. Heater exchanger Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-2-of-2) Change coolant after replacing
10. Coolant reservoir cap Pressure relief valve, checking, refer to «PRESSURE RELIEF VALVE IN CAP, CHECKING»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .
11. Coolant reservoir
12. Oil cooler Removing and installing, refer to «OIL COOLER»(/audi/a5/i-2007-2011/remont/lubrication-system/#32l-lubrication-engine-codes-cala-coupe-as-of-112007__oil-cooler) . Change coolant after replacing
13. After-run coolant pump -V51- Vehicles for countries with warm climates Removing and installing, refer to «AFTER-RUN COOLANT PUMP»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__after-run-coolant-pump) .
14. Non-return valve Arrow points in direction of flow
15. Non-return valve Arrow points in direction of flow

Scheme 11

1. Bolt 9 Nm
2. Bolt 20 Nm
3. Pulley, coolant pump
4. Coolant pump With gasket Removing and installing, refer to «COOLANT PUMP»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__coolant-pump) .
5. Bolt 9 Nm
6. Connecting piece For coolant hose
7. Gasket Replace
8. Gasket Replace
9. Coolant thermostat Removing and installing, refer to «THERMOSTAT»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) . Checking, refer to «THERMOSTAT, CHECKING»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__thermostat-checking) .
10. Bolt 9 Nm

Scheme 12

1. Coolant pipe, left With -17-, removing and installing, refer to «LEFT COOLANT PIPES»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__left-coolant-pipes) .
2. Bolt 9 Nm
3. O-ring Replace
4. Connecting hose
5. Bolts 9 Nm
6. Coolant pipe, front Removing and installing, refer to «FRONT COOLANT PIPE»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__front-coolant-pipe) .
7. Bolts 9 Nm
8. O-ring Replace
9. Retaining clip
10. Engine Coolant Temperature (ECT) sensor -G62- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .
11. Seal Replace
12. Coolant hose
13. Seal Replace
14. O-ring Replace
15. Coolant pipe, upper Removing and installing, refer to «UPPER COOLANT PIPE»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .
16. Bolt 9 Nm
17. Coolant pipe. left With -1-, removing and installing, refer to «LEFT COOLANT PIPES»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__left-coolant-pipes) .
18. Bolt 9 Nm
19. Coolant hoses

Scheme 13

1. Coolant hose
2. Bracket
3. Screws 9 Nm
4. Coolant hose
5. Bolt 4 Nm
6. After-run coolant pump -V51- Removing and installing, refer to «AFTER-RUN COOLANT PUMP»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__after-run-coolant-pump) .

RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW

Scheme 14

1. Coolant Fan Control (FC) control module -J293- Either separate or integrated in coolant fan -V7-, depending on equipment Separate Coolant Fan Control (FC) control module -J293-, removing and installing, refer to «COOLANT FAN CONTROL MODULE»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__coolant-fan-control-module).
2. Bolt 4.5 Nm
3. Bolt 5 Nm
4. Fan rib Removing and installing, refer to «FAN SHROUD»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007).
5. Coolant fan -V7- With integrated Coolant Fan Control (FC) control module -J293-, depending on equipment Removing and installing coolant fan -V7-, refer to «COOLANT FANS»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007).
6. Bolt 3.5 Nm
7. Rubber buffer
8. Rubber bushing For radiator
9. Coolant hose Lift retaining clamp to remove
10. O-ring Replace
11. O-ring Replace
12. Coolant hose Lift retaining clamp to remove Connect to radiator (Scheme 15)
13. Coolant hose To coolant reservoir
14. O-ring Replace
15. Radiator Removing and installing with fan shroud, refer to «RADIATOR»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__radiator). After replacing, replace entire amount of coolant
16. Retaining pin Disengage and remove using screwdriver
17. Rubber buffer
18. Radiator bracket
19. Bolt
20. O-ring Replace
21. Coolant hose Lift retaining clamp to remove Connect to radiator (Scheme 15)
22. Coolant fan 2 -V177- Not with 400 W fan activation Removing and installing, refer to «COOLANT FANS»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007).
23. Bolt 5 Nm

Scheme 15

Remove old O-ring -2- in coolant hose -3-.

Coat new O-ring with coolant additive and insert it in coolant hose.

Press coolant hose onto radiator -1- until it engages audibly.

Press coolant hose on again and pull to make sure connection is engaged correctly.

THERMOSTAT, CHECKING

Heat up removed thermostat in water.

COOLING SYSTEM, CHECKING FOR LEAKS

Special tools and workshop equipment required

1. Cooling system tester V.A.G 1274
2. Adapter V.A.G 1274/8
3. Adapter V.A.G 1274/9

Procedure

Proceed as follows

1. Engine at operating temperature.

Open coolant reservoir cap.

Position cooling system tester V.A.G 1274 with adapter V.A.G 1274/8 on coolant reservoir.

Scheme 16

Generate approximately 1 bar pressure using cooling system tester hand pump.

If pressure falls, search for leaks and correct problem.

Scheme 17

Attach cooling system tester V.A.G 1274 with adapter V.A.G 1274/9 to sealing cap.

Generate pressure with cooling system tester hand pump.

1. The pressure release valve must open at a positive pressure of 1.4 to 1.6 bar.

If pressure relief valve does not open as specified, replace cap.

COOLANT PUMP

Special tools and workshop equipment required

1. Pin wrench 3212

REMOVING

Remove front engine cover -bottom arrows-.

Scheme 18

Drain coolant, refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove ribbed belt, refer to RIBBED BELT .

Remove bolts for coolant pump ribbed belt pulley, using a spanner wrench 3212 to counterhold.

Scheme 19

Note. Place a cloth beneath to catch escaping coolant.

Remove coolant pump bolts -arrows- and coolant pump.

Scheme 20

INSTALLING

1. Tightening specifications, refer to «COOLANT PUMP, THERMOSTAT AND CONNECTING PIECE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Clean sealing surfaces, must be free of oil and grease.

Note. If the used coolant pump is reinstalled, apply a 1.5 mm thick sealant bead to the cleaned sealing surface in addition to the seal that has been vulcanized on.

Install ribbed belt, refer to RIBBED BELT .

Fill with coolant, refer to FILLING .

Drain coolant, refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove upper section of intake manifold, refer to Removal and Installation .

Remove front coolant pipe, refer to FRONT COOLANT PIPE .

Remove bolts -arrows-.

Scheme 21

Remove coolant thermostat with the connections.

1. Tightening specifications, refer to «COOLANT PUMP, THERMOSTAT AND CONNECTING PIECE ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace the seals

Install front coolant pipe, refer to FRONT COOLANT PIPE .

Install upper section of intake manifold, refer to Removal and Installation .

Fill with coolant, refer to FILLING .

1. Engine cold.

Briefly open coolant reservoir cap to reduce residual pressure in coolant system.

Remove front engine cover -bottom arrows-.

Disconnect electrical connector -2- on Engine Coolant Temperature (ECT) sensor -G62-.

Scheme 22

Note. Lay a cloth below to catch escaping coolant.

Remove retaining clip -1- and Engine Coolant Temperature (ECT) sensor -G62-.

Installation is in reverse order of removal, note the following

Note. Replace O-ring. To prevent coolant loss, immediately insert new Engine Coolant Temperature (ECT) sensor -G62- in support.

Check coolant level, refer to CHECK COOLANT LEVEL .

FRONT COOLANT PIPE

Special tools and workshop equipment required

1. Pin wrench 3212
2. Hose clamp pliers V.A.G 1921
3. Hose clamp pliers VAS 6340

Proceed as follows

Drain coolant, refer to COOLING SYSTEM, DRAINING AND FILLING , or remove after-run coolant pump -V51- -V51- if applicable, refer to AFTER-RUN COOLANT PUMP .

Remove air duct -arrows-.

Scheme 23

Remove ribbed belt, refer to, refer to RIBBED BELT .

Remove bolts for coolant pump ribbed belt pulley, using a spanner wrench 3212 to counter hold.

Remove left front wheel.

Remove left front wheel housing liner, refer to Description and Operation .

Remove bolts -arrows- and remove A/C compressor from bracket and lay it aside.

Scheme 24

Note. Ignore -1-.

Loosen hose clamp -3- and remove left coolant pipe bolts -1- and -2-.

Scheme 25

Tip coolant pump to left slightly -arrow- and remove it from upper coolant pipe.

Disconnect electrical connector -3- for Engine Coolant Temperature (ECT) sensor -G62-.

Scheme 26

Remove bolts -1, 2, 4 and 5-.

Remove front coolant pipe from coolant hoses -arrows-.

1. Tightening specifications, refer to «COOLANT PIPES ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace sealing rings. Secure all hose connections with hose clamps appropriate for the model .

Clean and smooth gasket sealing surfaces.

Coat gaskets with coolant additive and slide them onto coolant pipe.

Install left coolant pipes, refer to LEFT COOLANT PIPES .

Install A/C compressor, refer to Removal and Installation .

Install power steering pump ribbed belt pulley, refer to Description and Operation .

Install after-run coolant pump -V51-, refer to AFTER-RUN COOLANT PUMP .

Install front wheel housing liner, refer to Description and Operation .

Install coolant pump ribbed belt pulley, refer to COOLANT PUMP, THERMOSTAT AND CONNECTING PIECE ASSEMBLY OVERVIEW .

Install ribbed belt, refer to RIBBED BELT .

Install after-run coolant pump -V51-, refer to AFTER-RUN COOLANT PUMP .

Fill with coolant, refer to FILLING .

LEFT COOLANT PIPES

Special tools and workshop equipment required

1. Hose clamp pliers V.A.G 1921

Drain coolant, refer to COOLING SYSTEM, DRAINING AND FILLING or, in countries with hot climates, remove after-run coolant pump -V51-, refer to AFTER-RUN COOLANT PUMP .

Remove air conditioner compressor, refer to Removal and Installation .

Scheme 27

Remove bolts -arrows- and A/C compressor bracket.

Remove bolts -arrows-.

Scheme 28

Remove coolant pipes from coolant hoses -1- and -2-.

Note. The installation location is shown with the power steering pump removed.

1. Tightening specifications, refer to «COOLANT PIPES ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace O-rings. Secure all hose connections with hose clamps appropriate for the model .

Clean and smooth O-ring sealing surface.

Coat O-ring with coolant additive and slide it onto coolant pipe.

Install A/C compressor bracket, refer to RIBBED BELT ASSEMBLY OVERVIEW .

Install A/C compressor, refer to Removal and Installation .

Install after-run coolant pump -V51-, refer to AFTER-RUN COOLANT PUMP .

Fill with coolant, refer to FILLING .

Note. During installation, all cable ties must be reinstalled at the same location.

Drain coolant, refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove upper section of intake manifold, refer to Removal and Installation .

Remove bolts -arrows- and high pressure line protective plate -1-.

Scheme 29

Reduce fuel pressure in high pressure area, refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

Remove threaded connection -1-.

Scheme 30

Loosen union nuts -2- and -3- by counter holding at connections.

Remove bolts -arrows- on retaining plates and high pressure line.

Remove high pressure line connections -arrow-.

Scheme 31

Note. Lay a cloth below coolant pipe to catch escaping coolant.

Remove coolant hose -arrow- from coolant pipe.

Scheme 32

Remove bolt -1- and remove coolant pipe back out of cylinder block -arrow-.

1. Tightening specifications, refer to «COOLANT PIPES ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

Clean and smooth O-ring sealing surface.

Coat O-ring with coolant additive and slide it onto coolant pipe.

Install high pressure line, refer to Description and Operation .

Install upper section of intake manifold, refer to Removal and Installation .

Fill with coolant, refer to FILLING .

AFTER-RUN COOLANT PUMP

Special tools and workshop equipment required

1. Drip tray for workshop crane VAS 6208
2. Hose clamp pliers VAS 6340

Proceed as follows

Open coolant reservoir cap.

Remove noise insulation by loosening fasteners -1- and -2-.

Remove bolt -1- and disconnect electrical connector -2-.

Scheme 33

Place drip tray VAS 6208 under engine.

Remove after-run coolant pump -V51- from coolant hoses -arrows-.

1. Tightening specifications, refer to «AFTER-RUN COOLANT PUMP ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007) .

Installation is in reverse order of removal, note the following

Fill with coolant, refer to FILLING .

RADIATOR

Special tools and workshop equipment required

1. Drip tray for workshop crane VAS 6208
2. Used oil collecting and extracting device V.A.G 1782 for vehicles with automatic transmission

Proceed as follows

Note. When assembled correctly, radiator and condenser can show slight impressions on fins. This is not damage. Radiators or condensers should not be replaced because of slight impressions like these.

Remove noise insulation by loosening fasteners -1- and -2-.

Remove front bumper cover and bumper, refer to Removal and Installation .

Place drip tray VAS 6208 under engine.

Remove drain plug -1- and drain coolant.

Remove coolant hose -2- from radiator by raising retaining clip.

Remove connection -arrow- from radiator by removing the retaining clip.

Scheme 34

Disconnect coolant fan electrical connector -1- by sliding retainer back -arrow- and pressing release down.

Scheme 35

With Automatic Transmission

Scheme 36

Place used oil collecting and extracting device V.A.G 1782 under separating point.

Note. Follow the rules for clean working conditions when working automatic transmissions, refer to General Information .

Remove bolts -arrow- and disconnect ATF lines from transmission.

Note. To prevent ATF from leaking, secure all ATF lines to the top of the longitudinal member.

Continuation for All

Remove connections -1- and -2- from radiator by removing retaining clip.

Scheme 37

Remove bolts -arrows-.

Scheme 38

Remove air duct -1- from air filter housing intermediate flange -2-.

Release retaining tabs -A arrows- and remove left and right air ducts -1- upward -arrow B-.

Scheme 39

Release left and right radiator retaining pins and remove by pulling upward -arrows-.

Scheme 40

Remove left and right bolts -1- and remove radiator console with radiator from lock carrier -arrow-.

Scheme 41

Lower radiator slightly.

Have a second technician release retaining clamps -1- in direction of -arrow A- and remove condenser -2- upward out of mounts on radiator -B arrows-.

Scheme 42

Tip condenser with lines connected forward.

Remove radiator.

Press fan shroud left and right locking tabs at the same time -arrow- and remove fan shroud upward from radiator.

Scheme 43

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__radiator-and-coolant-fan-assembly-overview) .

Installation is in reverse order of removal, note the following

On vehicles with automatic transmission, install the ATF lines, refer to Description and Operation .

Install air duct on air filter housing intermediate flange, refer to Description and Operation .

Install bumper and front bumper cover, refer to Removal and Installation .

Connect coolant hose to connector on radiator (Scheme 15)

Fill with coolant, refer to FILLING .

Note. All of the coolant must be changed if the radiator was replaced.

On vehicles with automatic transmission, check ATF level, refer to General Information .

Proceed as follows

Remove noise insulation by loosening fasteners -1- and -2-.

Disconnect coolant fan electrical connector -1- by sliding retainer back -arrow- and pressing release down.

Remove bolts -1- and -2- and remove bumper cover noise insulation toward the rear.

Scheme 44

Remove left and right bolts -1-.

Note. Ignore -arrow-.

Remove bolts -1, 2, 3 and 5-.

Scheme 45

Lift lock carrier cover -4- and hang it on radiator grille.

Remove bolts -arrows-.

Remove air duct -1- from air filter housing intermediate flange -2-.

Release retaining tabs -A arrows- and tilt left and right air ducts -1- toward center of vehicle -arrow B-.

Release left and right radiator retaining pins and remove by pulling upward -arrows-.

Pull right side of radiator forward -arrow B-, then press right -arrow A- and pull then left side forward -arrow C-.

Scheme 46

Press fan shroud left and right locking tabs at the same time -arrow- and remove fan shroud upward from radiator.

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__radiator-and-coolant-fan-assembly-overview) .

Installation is in reverse order of removal, note the following

Install air duct on air filter housing intermediate flange, refer to Description and Operation .

Install lock carrier cover, refer to Removal and Installation .

Install bumper cover insulation, refer to Removal and Installation .

Install front noise insulation, refer to Description and Operation .

COOLANT FAN CONTROL MODULE

Note. The following description is based on a coolant fan with a separate coolant Fan Control (FC) control module -J293-.

Proceed as follows

Remove noise insulation by loosening fasteners -1- and -2-.

Remove coolant fan electrical connector -1- form bracket and disconnect it by sliding retainer back -arrow- and pressing release down.

Free up electrical wiring harness to coolant fan control module.

Disconnect electrical connectors -2- and -3-.

Scheme 47

Remove bolt -arrow- and coolant fan control module -1-.

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__radiator-and-coolant-fan-assembly-overview) .

Installation is in reverse order of removal, note the following

Note. Secure all hose connections with hose clamps appropriate for the model .

Install front noise insulation, refer to Description and Operation .

Proceed as follows

Note. During installation, all cable ties must be reinstalled at the same location.

Remove fan shroud, refer to FAN SHROUD .

Disconnect electrical connector -1-.

Scheme 48

Remove bolts -arrows- and left coolant fan.

Disconnect electrical connector -1-.

Scheme 49

Remove bolts -arrows- and right coolant fan.

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-112007__radiator-and-coolant-fan-assembly-overview) .

Installation is in reverse order of removal, note the following

Install fan shroud, refer to FAN SHROUD .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 50

Scheme 51

Scheme 52

1. Pin wrench 3212
2. Hose clamp pliers VAS 6340
3. Used oil collecting and extracting device V.A.G 1782

Scheme 53

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Adapter V.A.G 1274 tester V.A.G 1274/10
3. Hose clamp pliers V.A.G 1921
4. Cooling system charge unit VAS 6096
5. Drip tray for workshop crane VAS 6208
6. Refractometer T10007

Scheme 54

Special tools and workshop equipment required

1. Cooling system tester V.A.G 1274
2. Adapter V.A.G 1274/8
3. Adapter V.A.G 1274/9

See also:
• Description and Operation
• Description and Operation
• Removal and Installation
• OIL COOLER
• RIBBED BELT
• Removal and Installation
• Description and Operation
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• Removal and Installation
• General Information
• Description and Operation
• RADIATOR
• COOLANT PUMP
• ENGINE COOLANT TEMPERATURE SENSOR
• THERMOSTAT, CHECKING
• AFTER-RUN COOLANT PUMP
• LEFT COOLANT PIPES
• FRONT COOLANT PIPE
• COOLANT FAN CONTROL MODULE
• COOLING SYSTEM, DRAINING AND FILLING
• FILLING
• RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW