3.2l - Cooling System - Engine Code(s): Cala (coupe) (as of 12.2008) Audi A5 I

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.

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

DRAINING

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

Open coolant reservoir cap.

Remove front noise insulation -1-. Refer to Description and Operation .

Scheme 55

Place VAS 6208 under engine.

Remove drain plug -1- and drain the coolant.

Scheme 56

Note. Ignore -2-.

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

Scheme 57

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 guaranteed to about -25 °C (-13 °F) (to about -35 °C (-31 °F) in countries with extremely cold climates). 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% to provide freeze protection to about -40 °C (-40 °F). 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 re-used. Secure all hose connections with hose clamps appropriate for the model. Use the T10007 to determine the level of freeze protection in the coolant system.

Close drain plug -1-.

Note. Ignore -2-.

Install coolant hose on the oil cooler -arrow-.

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

Scheme 58

1. Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection down to -25 °C (-13 °F).
2. Coolant freeze and corrosion protection additive (50%) and water (50%) for freeze protection down to -35 °C (-31 °F).
3. Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection down to -40 °C (-40 °F).
4. For coolant freeze and corrosion protection additive.

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

Install the VAS 6096 on the 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 59

1. The suction jet pump generates pressure in the 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 the VAS 6096 coolant reservoir by pressure in the coolant system and the system is filled.

Remove VAS 6096 form V.A.G 1274/8 on coolant reservoir.

Connect V.A.G 1274/10 to the V.A.G 1274/8.

Scheme 60

Remove the center piece -2- or the entire plenum chamber cover, depending on the version. Refer to Removal and Installation .

Scheme 61

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

Scheme 62

Fill the coolant until it escapes from the coolant hose bleeder hole.

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

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

Close coolant reservoir cap.

Start engine.

Set the temperature to "HI" for all zones and set the fan speed as low as possible (0).

Switch the A/C compressor off by pressing the AC button.

1. The LED in the button must not come on.

Run engine at 2000 RPM for 3 minutes.

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

Run engine at 2000 RPM for 2 minutes.

Turn off engine and allow it to cool off.

Install front noise insulation. Refer to Description and Operation .

Scheme 63

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

RADIATOR AND COOLANT FAN

COOLANT HOSE CONNECTION DIAGRAM

Note. The arrows show the coolant flow direction.

Scheme 64

1. Radiator Change coolant after replacing
2. Coolant pump
3. Engine Coolant Temperature (ECT) Sensor -G62
4. Coolant Thermostat
5. Coolant Pump -V50- Activated by the Recirculation Pump Relay -J160- Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2)
6. Cylinder Head and Cylinder Block Change coolant after replacing
7. Coolant Switch-Off Valve Is controlled by the Auxiliary Heater Exhaust Gas Sensor -N422- The Auxiliary Heater Exhaust Gas Sensor -N422- is controlled by the Climatronic Control Module -J255-. Removing and installing, refer to «Removal and Installation»(/audi/a5/i-2007-2011/remont/automatic-hvac-system/#air-conditioning-coupe-1-of-2)
8. Bleeder Hole
9. Heater Core 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-122008)
11. Coolant Reservoir
12. Oil cooler Change coolant after replacing
13. After-Run Coolant Pump -V51- Vehicles for countries with warm climates
14. Non-Return Valve
15. Non-Return Valve

Scheme 65

1. Bolt 9 Nm
2. Bolt 20 Nm
3. Ribbed Belt Pulley for 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-122008__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 «COOLANT THERMOSTAT»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) Checking, refer to «THERMOSTAT, CHECKING»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008__thermostat-checking)
10. Bolt 9 Nm

Scheme 66

1. Left Coolant Pipe 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-122008__left-coolant-pipes)
2. Bolt 9 Nm
3. O-ring Replace
4. Connecting Hose
5. Bolts 9 Nm
6. Front Coolant Pipe 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-122008__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 -G62»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008)
11. Seal Replace
12. Coolant Hose
13. Seal Replace
14. O-ring Replace
15. Upper Coolant Pipe 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-122008)
16. Bolt 9 Nm
17. Left Coolant Pipe 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-122008__left-coolant-pipes)
18. Bolt 9 Nm
19. Coolant Hoses

Scheme 67

1. Coolant Hose
2. Bracket
3. Bolts 9 Nm
4. Coolant Hose
5. Bolt 4 Nm
6. After-Run Coolant Pump -V51- Removing and installing, refer to «AFTER-RUN COOLANT PUMP -V51»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008__after-run-coolant-pump-v51)

Scheme 68

1. Coolant Fan Control (FC) Module -J293- Separate or connected to the Coolant Fan -V7-, depending on vehicle equipment Separate Coolant Fan Control (FC) 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-122008__coolant-fan-control-module)
2. Bolt 4.5 Nm
3. Bolt 5 Nm
4. Fan rib Removing and installing: A4, together with the cooler, refer to. For the A5, refer to «FAN SHROUD»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008__fan-shroud).
5. Coolant Fan -V7- Separate or connected to the Coolant Fan Control Module -J293-, depending on vehicle equipment Removing and installing Coolant Fan -V7-, refer to «COOLANT FAN»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008)
6. Bolt 3.5 Nm
7. Rubber Buffer
8. Rubber Bushing For radiator
9. Coolant Hose Lift retaining clamp to remove Connect to radiator (Scheme 69)
10. O-ring Replace
11. O-ring Replace
12. Coolant Hose Lift the retaining clamp to remove Connect to radiator (Scheme 69)
13. Coolant Hose To coolant reservoir
14. O-ring Replace
15. Radiator Removing and installing: A4, together with the fan shroud, refer to. For the A5, refer to «COOLER»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008__cooler). After replacing, replace entire amount of coolant
16. Retaining Pin Disengage and remove using screwdriver
17. Rubber Buffer
18. Radiator Bracket
19. Bolt 3.5
20. O-ring Replace
21. Coolant Hose Lift the retaining clamp to remove Connect to the radiator (Scheme 69)
22. Coolant Fan 2 -V177- Not with the 400 W fan activation Separate or connected to the coolant fan control module, depending on vehicle equipment Removing and installing, refer to «COOLANT FAN»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008)
23. Bolt 5 Nm

Scheme 69

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

Moisten new O-ring with coolant and install it in the coolant hose.

Press coolant hose onto the connection -1- until it engages audibly.

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

FASTENER TIGHTENING SPECIFICATIONS

THERMOSTAT, CHECKING

Heat up the removed thermostat in water.

COOLING SYSTEM, CHECKING FOR LEAKS

Special tools and workshop equipment required

1. Cooling System Tester V.A.G 1274 B
2. Adapter V.A.G 1274/8
3. Adapter V.A.G 1274/9

Procedure

1. Engine at operating temperature.

Open coolant reservoir cap.

Position V.A.G 1274 B with V.A.G 1274/8 on coolant reservoir.

Scheme 70

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

If pressure falls, search for leaks and correct problem.

Scheme 71

Attach V.A.G 1274 B with V.A.G 1274/9 to sealing cap.

Generate pressure with cooling system tester hand pump.

1. The pressure release valve must open at 1.4 to 1.6 bar (20.30 to 23.20 psi).

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

REMOVAL AND INSTALLATION

Audi A5

COOLANT PUMP

Special tools and workshop equipment required

1. Spanner Wrench 3212

REMOVING

Remove front engine cover -bottom arrows-.

Scheme 72

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

Scheme 73

Remove ribbed belt. Refer to RIBBED BELT .

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

Note. Lay a cloth below to catch escaping coolant.

Remove coolant pump bolts -arrows- and the coolant pump.

Scheme 74

INSTALLING

1. Tightening specifications. Refer to «COOLANT PUMP, THERMOSTAT AND CONNECTING PIECE OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

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

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 the intake manifold. Refer to Removal and Installation .

Scheme 75

Remove front coolant pipe. Refer to FRONT COOLANT PIPE .

Remove bolts -arrows-.

Scheme 76

Remove coolant thermostat with the connections.

1. Tightening specifications. Refer to «COOLANT PUMP, THERMOSTAT AND CONNECTING PIECE OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

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 the intake manifold. Refer to Removal and Installation .

Fill with coolant, refer to FILLING .

1. Engine cold.

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

Remove front engine cover -bottom arrows-.

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

Scheme 77

Note. Lay a cloth below to catch escaping coolant.

Remove retaining clip -1- and ECT sensor --.

Installation is in reverse order of removal, note the following

Note. Replace O-ring. To prevent coolant loss, immediately insert new ECT sensor -- in support.

Check coolant level, refer to CHECK COOLANT LEVEL .

FRONT COOLANT PIPE

Special tools and workshop equipment required

1. Spanner Wrench 3212

Hose Clamp Pliers V.A.G 1921

Hose Clamp Pliers VAS 6340

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

Remove air duct -arrows-.

Scheme 78

Remove ribbed belt. Refer to RIBBED BELT .

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

Remove left front wheel.

Remove left front wheel housing liner. Refer to Description and Operation .

Remove bolts -arrows- and remove the Air Conditioning (A/C) compressor from the bracket and lay it aside.

Scheme 79

Note. Ignore -1-.

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

Scheme 80

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

Vehicles with secondary air injection system: Remove the front secondary air hose -arrow- from its bracket and disconnect it; do to so press the release buttons.

Scheme 81

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

Scheme 82

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

Remove front coolant pipe from coolant hoses -arrows-.

1. Tightening specifications. Refer to «COOLANT PIPES OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace the seal and O-ring. Secure all hose connections with hose clamps appropriate for the model.

Clean and smooth the gasket sealing surfaces.

Coat the gaskets with coolant and slide them onto the 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 Removal and Installation .

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

Install front wheel housing liner. Refer to Description and Operation .

Mount front wheel. Refer to General Information .

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

Install ribbed belt. Refer to RIBBED BELT .

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

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 the after-run coolant pump -V51- AFTER-RUN COOLANT PUMP -V51 .

Remove air conditioner compressor. Refer to Removal and Installation .

Scheme 83

Remove bolts -arrows- and the Air Conditioning (A/C) compressor bracket.

Scheme 84

Remove bolts -arrows-.

Scheme 85

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

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

1. Tightening specifications. Refer to «COOLANT PIPES OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

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 and slide it onto the coolant pipe.

Install A/C compressor bracket. Refer to RIBBED BELT DRIVE OVERVIEW .

Install A/C compressor. Refer to Removal and Installation .

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

Fill with coolant, refer to FILLING .

Note. During installation, all cable ties must be re-installed at the same location.

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

Remove upper section of the intake manifold. Refer to Removal and Installation .

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

Scheme 86

Vehicles with secondary air injection system: Remove the front secondary air hose -arrow- from its bracket and disconnect it; do to so press the release buttons.

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

Remove threaded connection -1-.

Scheme 87

Loosen union nuts -2- and -3- by counterholding at the connections.

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

Remove high pressure line connections -arrow-.

Scheme 88

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

Remove coolant hose -arrow- from the coolant pipe.

Scheme 89

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

1. Tightening specifications. Refer to «COOLANT PIPES OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace O-rings.

Clean and smooth O-ring sealing surface.

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

Install high pressure line. Refer to Removal and Installation .

Install upper section of the intake manifold. Refer to Removal and Installation .

Fill with coolant, refer to FILLING .

AFTER-RUN COOLANT PUMP -V51

Special tools and workshop equipment required

1. Drip Tray for Workshop Crane VAS 6208
2. Hose Clamp Pliers VAS 6340

Open coolant reservoir cap.

Remove front noise insulation -1-. Refer to Description and Operation .

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

Scheme 90

Place VAS 6208 under engine.

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

1. Tightening specifications. Refer to «AFTER-RUN COOLANT PUMP OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Fill with coolant. Refer to FILLING .

COOLANT FAN CONTROL MODULE

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

Remove front noise insulation -1-. Refer to Description and Operation .

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

Scheme 91

Free up the electrical wiring harness to the coolant fan control module.

Disconnect electrical connectors -2- and -3-.

Scheme 92

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

1. Tightening specifications. Refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Install front noise insulation. Refer to Description and Operation .

Note. During installation, all cable ties must be re-installed at the same location.

A4: Cooler with fan shroud, Removing. Refer to .

A5: Remove fan shroud. Refer to FAN SHROUD .

Disconnect electrical connector -1-.

Scheme 93

Remove the bolts -arrows- and left Coolant Fan -V7-.

Coolant Fan 2 -V177- with separate coolant fan control module

Disconnect electrical connector -1-.

Scheme 94

Remove bolts -arrows- and the right Coolant Fan 2 -V177-.

Coolant Fan 2 -V177- with coolant fan control module

Remove bolts -arrows- on the right Coolant Fan 2 -V177-.

Scheme 95

Free up electrical wiring harness.

Unclip the coolant fan control module -1- from the fan shroud and remove the fan with the control module.

1. Tightening specifications. Refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

A4: Install the cooler with the fan shroud. Refer to .

A5: Install fan shroud. Refer to FAN SHROUD .

COOLER

Special tools and workshop equipment required

1. Used Oil Collecting and Extracting Device V.A.G 1782 for vehicles with multitronic 0AW or automatic transmission 0B6
2. Engine Bung Set VAS 6122 for vehicles with multitronic 0AW or automatic transmission 0B6
3. Drip Tray for Workshop Crane VAS 6208

Note. If there are small impressions on the fins. Refer to COOLERS AND CONDENSERS .

Remove front noise insulation -1-. Refer to Description and Operation .

Remove the front bumper cover and the impact absorber. Refer to Removal and Installation .

Scheme 96

Place VAS 6208 under engine.

Remove drain plug -1- and drain the coolant.

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

Lift the clamp -arrow- and remove the connection from the radiator.

Scheme 97

Push the retainer back -arrow-, press the release down and disconnect the coolant fan connectors -1 and 2-, if applicable.

Scheme 98

Vehicles with Multitronic transmission 0AW/automatic transmission 0B6

Place the V.A.G 1782 under the disconnection point.

Note. Follow the rules for clean working conditions when working on the transmission. Refer to General Information .

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

Scheme 99

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

Seal the open lines and connections with clean plugs from the VAS 6122.

All Vehicles

Open the clamps -1 and 2- and remove the connection from the radiator.

Scheme 100

Remove bolts -arrows-.

Scheme 101

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

If applicable, release the clamps -arrow A- and tilt the power steering coolant hose -1- forward -arrow B-.

Scheme 102

Pull the power steering coolant hose upward off the condenser and lay it on the engine.

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

Scheme 103

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

Scheme 104

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

Scheme 105

Lower the radiator slightly.

Note. Evacuate the refrigerant and remove both lines in order to slide the condenser upward.

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

Scheme 106

Tip the condenser with the lines connected forward.

Remove the radiator.

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

Scheme 107

1. Tightening specifications. Refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Install ATF lines. Refer to Removal and Installation .

Install air duct on the air filter housing intermediate flange. Refer to Description and Operation .

Install the impact absorber and front bumper cover. Refer to Removal and Installation .

Connect the coolant hose with the connector coupling (Scheme 69)

Fill with coolant. Refer to FILLING .

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

Vehicles with multitronic 0AW or automatic transmission 0B6: Check ATF level. Refer to General Information .

FAN SHROUD

Special tools and workshop equipment required

1. Used Oil Collecting and Extracting Device V.A.G 1782 for vehicles with multitronic 0AW or automatic transmission 0B6
2. Engine Bung Set VAS 6122 for vehicles with multitronic 0AW or automatic transmission 0B6

Remove front noise insulation -1-. Refer to Description and Operation .

Push the retainer back -arrow-, press the release down and disconnect the radiator fan connectors -1- and -2-, if applicable.

Vehicles with Multitronic transmission 0AW/automatic transmission 0B6

Place the V.A.G 1782 under the disconnection point.

Note. Follow the rules for clean working conditions when working on the transmission. Refer to General Information .

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

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

Seal the open lines and connections with clean plugs from the VAS 6122.

All Vehicles

Remove bolts -1 and 2- and remove the bumper cover end panel toward the rear.

Scheme 108

Remove left and right bolts -1-.

Note. Disregard -arrow-.

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

Scheme 109

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

Remove bolts -arrows-.

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

If applicable, release the clamps -arrow A- and tilt the power steering coolant hose -1- forward -arrow B-.

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

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

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

Scheme 110

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

1. Tightening specifications. Refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/a5/i-2007-2011/remont/cooling-fan/#32l-cooling-system-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Install air duct on the air filter housing intermediate flange. Refer to Description and Operation .

Install lock carrier cover. Refer to Removal and Installation .

Install bumper cover end panel. Refer to Removal and Installation .

Install front noise insulation. Refer to Description and Operation .

Scheme 111

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

Special tools and workshop equipment required

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

1. Cooling System Tester V.A.G 1274 B
2. Adapter V.A.G 1274/9
3. Spanner Wrench 3212
4. Hose Clamp Pliers VAS 6340
5. Used Oil Collecting and Extracting Device V.A.G 1782
6. Engine Bung Set VAS 6122

See also:
• Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• RIBBED BELT
• Removal and Installation
• Removal and Installation
• General Information
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• COOLERS AND CONDENSERS
• Removal and Installation
• General Information
• Removal and Installation
• PRESSURE RELIEF VALVE IN CAP, CHECKING
• COOLANT PUMP
• THERMOSTAT, CHECKING
• LEFT COOLANT PIPES
• FRONT COOLANT PIPE
• AFTER-RUN COOLANT PUMP -V51
• COOLANT FAN CONTROL MODULE
• FAN SHROUD
• COOLER
• COOLING SYSTEM, DRAINING AND FILLING
• FILLING