3.2l - Cooling System - Engine Code(s): Calb Audi Q5 I

COOLING SYSTEM, DRAINING AND FILLING

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Adapter V.A.G 1274/10
3. Hose Clip Pliers V.A.G 1921
4. Cooling System Charge Unit VAS 6096
5. Drip Tray VAS 6208
6. Refractometer T10007

Draining

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

Open the coolant reservoir cap.

Remove the front noise insulation -1-. Refer to Removal and Installation .

Scheme 67

Place the VAS 6208 under the engine.

Remove the drain plug -1- and drain the coolant.

Scheme 68

Note. Ignore -2-.

Remove the coolant hose from the engine oil cooler by loosening the hose clamp -arrow- and letting the remaining coolant drain out.

Scheme 69

Filling

1. Ignition turned 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. Protection against frost must be assured down to approximately -25 °C (-13 °F) (in arctic climatic countries down to approximately -35 °C (-31 °F)). 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 for the heater, cylinder head, cylinder head seal or cylinder block were replaced. If the coolant is contaminated. Dirty coolant may not be used again. Secure all hose connections with hose clamps of the same type as those equipped by the factory. Use the T10007 to determine the level of freeze protection in the coolant system.

Close the drain plug -1-.

Note. Ignore -2-.

Install the coolant hose on the oil cooler -arrow-.

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

Scheme 70

1. Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection up 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).

Attach V.A.G 1274/8 to the 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 (87 psi) pressure.

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

Scheme 71

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

Briefly open valve -A- by turning lever in direction of flow so that hose on the 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 the display instrument must remain in the green region, then sufficient vacuum in the cooling system is obtained for the upcoming filling.

Note. If the 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 the VAS 6096 form the V.A.G 1274/8 on coolant reservoir.

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

Scheme 72

Fill with coolant until the coolant system tester tube is full. Fill again during the bleeding procedure if necessary.

Remove the gasket -3-.

Scheme 73

Open the clips -1- and remove the plenum chamber cover -2-.

Pull back the coolant hose for the heater heat exchanger in order to loosen the hose clamp.

Scheme 74

As soon as coolant starts to come out of the vent hole -arrow-, attach the coolant hose to the connection and tighten the clamp.

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

Close the cap on the coolant reservoir until it latches.

Start the engine.

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

Press the AC button to turn off the A/C compressor.

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

Run the engine at 2000 RPM for 3 minutes.

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

Run the engine at 2000 RPM for 2 minutes.

Turn off engine and allow it to cool off.

Install the noise insulation. Refer to Removal and Installation .

Scheme 75

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

Scheme 76

1. Coolant Hose
2. Bracket
3. Bolts 9 Nm
4. Coolant Hose
5. Bolt 4 Nm
6. After-Run Coolant Pump -V51- Vehicles for countries with warm climates Removing and installing, refer to «AFTER-RUN COOLANT PUMP -V51»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__after-run-coolant-pump-v51)

COOLANT HOSE CONNECTION DIAGRAM

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory. The arrows on the coolant pipes and ends of coolant hoses must align.

Vehicles Without Auxiliary Heater

Note. The arrows show the coolant flow direction.

Scheme 77

1. Radiator Change coolant after replacing
2. Coolant Pump
3. Engine Coolant Temperature 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/q5/i-2008-2012/remont/automatic-hvac-system/#air-conditioning-as-of-052012-2-of-2)
6. Cylinder Head and Cylinder Block Change coolant after replacing
7. Coolant Switch-Off Valve Is controlled by the climatronic refrigerant shut-off valve -N422- The climatronic refrigerant shut-off valve is controlled by the climatronic control module -J255-. Removing and installing, refer to «Removal and Installation»(/audi/q5/i-2008-2012/remont/automatic-hvac-system/#air-conditioning-as-of-052012-2-of-2)
8. Bleeder Hole
9. Heat Exchanger for Heater Unit Removing and installing, refer to «Removal and Installation»(/audi/q5/i-2008-2012/remont/automatic-hvac-system/#air-conditioning-as-of-052012-2-of-2) Change coolant after replacing
10. Coolant Reservoir Cap Pressure relief valve, checking «PRESSURE RELIEF VALVE IN CAP, CHECKING»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb)
11. Coolant Reservoir
12. Engine 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 78

1. Left Coolant Pipe With -17-, removing and installing, refer to «LEFT COOLANT PIPES»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__left-coolant-pipes)
2. Bolt 9 Nm
3. O-ring Replace
4. Connecting Hose
5. Screws 9 Nm
6. Front Coolant Pipe Removing and installing, refer to «FRONT COOLANT PIPE»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__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/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__engine-coolant-temperature-sensor-g62)
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/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__upper-coolant-pipe)
16. Bolt 9 Nm
17. Left Coolant Pipe With -1-, removing and installing, refer to «LEFT COOLANT PIPES»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__left-coolant-pipes)
18. Bolt 9 Nm
19. Coolant Hoses

Scheme 79

1. Bolt 9 Nm
2. Bolt 20 Nm
3. Coolant Pump Ribbed Belt Pulley
4. Coolant Pump With gasket Removing and installing, refer to «COOLANT PUMP»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__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/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__coolant-thermostat) Checking, refer to «THERMOSTAT, CHECKING»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__thermostat-checking)
10. Bolt 9 Nm

RADIATOR AND COOLANT FAN OVERVIEW

Scheme 80

1. Coolant Fan Control (FC) Module -J293- Either separate or integrated in the coolant fan -V7-, depending on equipment Separate coolant fan control module, removing and installing, refer to «COOLANT FAN CONTROL MODULE 2 -J671»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__coolant-fan-control-module-2-j671)
2. Bolt 4.5 Nm
3. Bolt 5 Nm
4. Fan Rib Removing and installing, refer to «FAN SHROUD»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__fan-shroud)
5. Coolant Fan -V7- With integrated coolant fan control module, depending on equipment Removing and installing coolant fan, refer to «COOLANT FAN -V7- AND COOLANT FAN 2 -V177»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__coolant-fan-v7-and-coolant-fan)
6. Bolt 3.5 Nm
7. Rubber Buffer
8. Rubber Bushing For radiator
9. Coolant Hose Lift the retaining clamp to remove Connect to the radiator (Scheme 81)
10. O-ring Replace
11. O-ring Replace
12. Coolant Hose Lift the retaining clamp to remove Connect to the radiator (Scheme 81)
13. Coolant Hose To the coolant reservoir
14. O-ring Replace
15. Radiator Removing and installing with the fan shroud, refer to «RADIATOR»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__radiator) Change coolant after replacing
16. Retaining Pin Disengage and remove using screwdriver
17. Rubber Buffer
18. Radiator Bracket
19. Bolt
20. O-ring Replace
21. Coolant Hose Lift the retaining clamp to remove Connect to the radiator (Scheme 81)
22. Coolant Fan 2 -V177- Not with the 400 W fan activation Removing and installing, refer to «COOLANT FAN -V7- AND COOLANT FAN 2 -V177»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__coolant-fan-v7-and-coolant-fan)
23. Bolt 5 Nm

Scheme 81

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

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

Press the 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 the coolant reservoir cap.

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

Scheme 82

Generate approximately 1 bar (14.50 psi) pressure using the cooling system tester hand pump.

If pressure falls, search for leaks and correct problem.

Scheme 83

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.

AFTER-RUN COOLANT PUMP -V51

Special tools and workshop equipment required

1. Drip Tray VAS 6208
2. Hose Clip Pliers VAS 6340

Removing

Open the coolant reservoir cap.

Remove the front noise insulation -1-. Refer to Removal and Installation .

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

Scheme 84

Place the VAS 6208 under the engine.

Open the clamps -arrows- and remove the after-run coolant pump from the coolant hoses.

Installing

1. Tightening specification, refer to «AFTER-RUN COOLANT PUMP -V51- OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb) .

Install in reverse order, paying attention to the following

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Install the noise insulation. Refer to Removal and Installation .

Fill the engine with coolant FILLING .

COOLANT FAN -V7- AND COOLANT FAN 2 -V177

Removing

Note. When installing, bring all cable ties back to the same positions.

Remove fan shroud. Refer to FAN SHROUD .

Disconnect the connector -1-.

Scheme 85

Remove the bolts -arrows- and the left coolant fan.

Disconnect the connector -1-.

Scheme 86

Remove the bolts -arrows- and the right coolant fan.

Installing

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__radiator-and-coolant-fan-overview) .

Install in reverse order, paying attention to the following

Install fan shroud. Refer to FAN SHROUD .

COOLANT FAN CONTROL MODULE 2 -J671

Note. The following description is based on a coolant fan with a separate coolant fan control module.

Removing

Remove the front noise insulation -1-. Refer to Removal and Installation .

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

Scheme 87

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

Disconnect the connectors -2 and 3-.

Scheme 88

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

Installing

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__radiator-and-coolant-fan-overview) .

Install in reverse order, paying attention to the following

Install the noise insulation. Refer to Removal and Installation .

COOLANT THERMOSTAT

Removing

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

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

Scheme 89

Remove the front coolant pipe. Refer to FRONT COOLANT PIPE .

Remove the bolts -arrows-.

Scheme 90

Remove the coolant thermostat with the connections.

Installing

1. Tightening specification, refer to «COOLANT PUMP, COOLANT THERMOSTAT AND CONNECTING PIECE OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb) .

Install in reverse order, paying attention to the following

Note. Replace the gasket.

Install front coolant pipe. Refer to FRONT COOLANT PIPE .

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

Fill the engine with coolant FILLING .

COOLANT PUMP

Special tools and workshop equipment required

1. Spanner Wrench 3212

Removing

Remove the front engine cover -bottom arrows-.

Scheme 91

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

Scheme 92

Remove ribbed belt. Refer to RIBBED BELT .

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

Note. Lay a cloth below to catch escaping coolant.

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

Scheme 93

Installing

1. For the correct tightening specifications, refer to «COOLANT PUMP, COOLANT THERMOSTAT AND CONNECTING PIECE OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb) .

Install in reverse order, paying attention to the following

Clean the sealing surfaces; they must be free of oil and grease.

Install the ribbed belt. Refer to RIBBED BELT .

Fill the engine with coolant FILLING .

ENGINE COOLANT TEMPERATURE SENSOR -G62

Removing

1. Engine cold.

Quickly open the coolant reservoir cap and release any remaining pressure in the cooling system and then close it again.

Remove the front engine cover -bottom arrows-.

Disconnect the connector -2-.

Scheme 94

Note. Lay a cloth below to catch escaping coolant.

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

Installing

Install in reverse order, paying attention to the following

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

CHECK THE COOLANT LEVEL .

FAN SHROUD

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782
2. Engine Bung Set VAS 6122
3. Drip Tray VAS 6208

Removing

Remove the front noise insulation -1-. Refer to Removal and Installation .

Place the VAS 6208 under the engine.

Remove the drain plug -1- on the connection and drain the coolant.

Note. Ignore -2-.

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

Free up electrical wiring harness.

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

Scheme 95

Note. Be sure to follow the cleanliness guidelines. Refer to General Information .

Remove the 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 any open lines and connections with a clean plug from the VAS 6122.

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

Scheme 96

Remove the spreader clips -arrows- carefully push the pin -1- into the spreader clip -arrow A- to dimension -x-.

Scheme 97

1. Dimension -x- = 5 mm.

Remove the spreader clip -2- and the pin.

Remove the bolts -arrows-.

Scheme 98

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

Open the hook -arrow A- with a screwdriver -1-.

Scheme 99

Remove the air grille -2- from the bumper cover -arrow B-.

Repeat the procedure on the other side of the vehicle.

Open the latches -arrows- and remove the upper air duct -1-.

Scheme 100

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

Scheme 101

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

Scheme 102

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

Scheme 103

Remove the upper radiator forward.

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

Scheme 104

Installing

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__radiator-and-coolant-fan-overview) .

Install in reverse order, paying attention to the following

Install the air duct on the air filter housing intermediate flange. Refer to Removal and Installation .

Install the lock carrier cover and the bumper cover noise insulation. Refer to Removal and Installation .

Tighten the ATF lines. Refer to Removal and Installation .

Connect the coolant hose to the coupling. (Scheme 81)

Fill the engine with coolant FILLING .

Check the ATF level. Refer to Diagnosis and Testing .

Install the noise insulation. Refer to Removal and Installation .

FRONT COOLANT PIPE

Special tools and workshop equipment required

1. Spanner Wrench 3212

Hose Clip Pliers V.A.G 1921

Hose Clip Pliers VAS 6340

Removing

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

Remove the air duct -arrows-.

Scheme 105

Remove ribbed belt. Refer to RIBBED BELT .

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

Remove the left front wheel.

Remove the left front wheel housing liner. Refer to Removal and Installation .

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

Scheme 106

Note. Ignore -1-.

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

Scheme 107

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

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

Scheme 108

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

Open the clamp, loosen the hose clamp and remove the front coolant pipe from the coolant hoses -arrows-.

Installing

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb) .

Install in reverse order, paying attention to the following

Note. Replace sealing rings. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Clean and smooth the gasket sealing surfaces.

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

Connect the coolant hose to the coupling. (Scheme 81)

Install the left coolant pipes. Refer to LEFT COOLANT PIPES .

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

Install the front wheel housing liner. Refer to Removal and Installation .

Mount the front wheel. Refer to Removal and Installation .

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

Install the ribbed belt. Refer to RIBBED BELT .

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

Fill the engine with coolant FILLING .

LEFT COOLANT PIPES

Special tools and workshop equipment required

1. Hose Clip Pliers V.A.G 1921

Removing

Drain the 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 Conditioning (A/C) compressor. Refer to Removal and Installation .

Scheme 109

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

Scheme 110

Remove the bolts -arrows-.

Scheme 111

Remove the coolant pipes from the coolant hoses by loosening the hose clamps -1 and 2-.

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

Installing

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb) .

Install in reverse order, paying attention to the following

Note. Replace the O-ring. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Clean and smooth the O-ring sealing surface.

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

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

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

Install After-Run Coolant Pump -V51-. Refer to AFTER-RUN COOLANT PUMP -V51 .

Fill the engine with coolant FILLING .

RADIATOR

Special tools and workshop equipment required

1. Oil Collecting and Extracting Device V.A.G 1782
2. Engine Bung Set VAS 6122
3. Drip Tray VAS 6208

Removing

Note. The radiator and condenser may have small indentations on the fins even when installed correctly. It is not damage. Radiators or condensers should not be replaced because of slight impressions like these.

Remove the front noise insulation -1-. Refer to Removal and Installation .

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

Place the VAS 6208 under the engine.

Remove the drain plug -1- and drain the coolant.

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

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

Scheme 112

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

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

Note. Be sure to follow the cleanliness guidelines. Refer to General Information .

Remove the 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 any open lines and connections with a clean plug from the VAS 6122.

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

Remove the bolts -arrows-.

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

Open the latches -arrows- and remove the upper air duct -1-.

Note the following information while releasing the retaining tabs -A arrows- and removing the left and right air ducts -1- -arrow B-.

Note. Cut open the air duct around the refrigerant line with an edge cutter -arrow-.

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

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

Scheme 113

Lower the radiator slightly.

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

Scheme 114

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.

Installing

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb__radiator-and-coolant-fan-overview) .

Install in reverse order, paying attention to the following

Install the ATF lines. Refer to Removal and Installation .

Install the air duct on the air filter housing intermediate flange. Refer to Removal and Installation .

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

Connect the coolant hose to the coupling. (Scheme 81)

Fill the engine with coolant FILLING .

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

Check the ATF level. Refer to Diagnosis and Testing .

Install the noise insulation. Refer to Removal and Installation .

UPPER COOLANT PIPE

Removing

Note. When installing, bring all cable ties back to the same positions.

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

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

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

Scheme 115

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

Scheme 116

Reduce fuel pressure in high pressure area. Refer to General Information .

Remove the threaded connection -1-.

Scheme 117

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

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

Remove the high pressure line connections -arrow-.

Scheme 118

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

Open the clamp -2- and remove the coolant hose form the coolant pipe.

Scheme 119

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

Installing

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/q5/i-2008-2012/remont/cooling-fan/#32l-cooling-system-engine-codes-calb) .

Install in reverse order, paying attention to the following

Note. Replace the O-rings.

Clean and smooth the O-ring sealing surface.

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

Connect the coolant hose to the coupling. (Scheme 81)

Install the high pressure line. Refer to Removal and Installation .

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

Fill engine with coolant FILLING .

Scheme 120

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Adapter V.A.G 1274/10
3. Hose Clip Pliers V.A.G 1921
4. Cooling System Charge Unit VAS 6096
5. Drip Tray VAS 6208
6. Refractometer T10007

Special tools and workshop equipment required

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

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

See also:
• Removal and Installation
• Removal and Installation
• Removal and Installation
• RIBBED BELT
• General Information
• Removal and Installation
• Removal and Installation
• RIBBED BELT DRIVE OVERVIEW
• AFTER-RUN COOLANT PUMP -V51
• PRESSURE RELIEF VALVE IN CAP, CHECKING
• LEFT COOLANT PIPES
• FRONT COOLANT PIPE
• ENGINE COOLANT TEMPERATURE SENSOR -G62
• UPPER COOLANT PIPE
• COOLANT PUMP
• COOLANT THERMOSTAT
• THERMOSTAT, CHECKING
• COOLANT FAN CONTROL MODULE 2 -J671
• FAN SHROUD
• COOLANT FAN -V7- AND COOLANT FAN 2 -V177
• RADIATOR
• RADIATOR AND COOLANT FAN OVERVIEW
• FILLING
• COOLING SYSTEM, DRAINING AND FILLING