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3.0l - Cooling System - Engine Code(s): Cata Audi Q7 4L рестайлинг

Cooling Fan 96 illustrations ~7136 words

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. Drip Tray VAS 6208
  4. Cooling System Charge Unit VAS 6096
  5. Hose Clip Pliers VAS 6362
  6. Refractometer T10007
  7. Vehicle Diagnosis Tester for vehicles built through 05.10

Draining

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

On a vehicle with air suspension, activate vehicle lift mode. Refer to General Information .

WARNINGRisk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.

Open the coolant reservoir cap.

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

Scheme 70

Scheme 70
Scheme 70

Place the VAS 6208 under the engine.

Scheme 71

Scheme 71
Scheme 71

Remove the coolant hose from the left coolant pipe by loosening the hose clamp -arrow- and letting the coolant drain out.

Vehicles Built through 05.10

Remove the right lower coolant hose from the radiator by lifting the clamp -1- and let the coolant drain out.

Scheme 72

Scheme 72
Scheme 72

Note. Ignore -2-.

Vehicles Built from 06.10

Remove the right lower coolant hose from the radiator by lifting the clamp -1- and let the coolant drain out.

Scheme 73

Scheme 73
Scheme 73

Note. Ignore -2 and 3-.

All Vehicles

Loosen the hose clamps, remove the coolant hoses from the heat exchanger -arrows- and let the coolant drain out.

Scheme 74

Scheme 74
Scheme 74

Remove the coolant hose from the right coolant pipe by loosening the clamp -arrow- and letting any remaining coolant drain out.

Scheme 75

Scheme 75
Scheme 75

FILLING

  1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .
  2. Ignition switched off.

Note. The cooling system is filled year year-round with a mixture of water and coolant additive. Mixture ratio COOLANT MIXTURE RATIO . Only use specified coolant. 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. Coolant with the correct mixture ratio prevents freezing and corrosion damage and calcium deposits. They also raise the boiling point. The cooling system must be filled with coolant additive year-round. Refer to COOLANT MIXTURE RATIO . 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. Coolant additive portion must be at least 40%. When stronger freeze protection is needed due to the climate, the portion of coolant additive can be increased up to 60% (freeze protection down to approximately -40 °C (-40 °F)). Otherwise the freeze protection and cooling effect are reduced. Only use clean drinking water for mixing coolant. If radiator, heat exchanger, cylinder head or head seal or cylinder block were replaced, do not reuse used coolant. Dirty coolant may not be used again. Use the refractometer T10007 to check the freeze protection in the cooling system.

COOLANT MIXTURE RATIO

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

Connect the coolant hose -arrow- and connector coupling to the right coolant pipe. (Scheme 96)

Connect coolant hoses to coolant pipes for the heater heat exchanger -arrows-.

Vehicles Built through 05.10

Connect the coolant hose -1- and the lower right release coupling to the radiator. (Scheme 96)

Vehicles Built from 06.10

Connect the coolant hose -1- and the lower right release coupling to the radiator. (Scheme 96)

All Vehicles

Connect the coolant hose -arrow- to the left coolant pipe.

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

Scheme 76

Scheme 76
Scheme 76

Attach the 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 77

Scheme 77
Scheme 77
  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 the 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 the display instrument must remain in the green region, then the sufficient vacuum in the cooling system is obtained for the upcoming 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 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 78

Scheme 78
Scheme 78

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

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Scheme 79

Scheme 79
Scheme 79

Open the vent plug -arrow- on the top of the left coolant pipe until the coolant is allow to come out until there are no bubbles.

Scheme 80

Scheme 80
Scheme 80

Close the bleeder screw.

Open the front vent plug -arrow- on the engine and let the coolant drain out until there are no bubbles.

Scheme 81

Scheme 81
Scheme 81

Close the bleeder screw.

Vehicles Built through 05.10

Connect the vehicle diagnosis tester, turn on the ignition and select OBD .

Select the following menu points in vehicle on board diagnostic

  1. "01- Engine electronics"
  2. "Output Diagnostic Test Mode"

Remove the cover -2- from the guide in the lock carrier -1- -arrows A-.

Scheme 82

Scheme 82
Scheme 82

Remove the side cover on the bumper and radiator grille -arrows B-.

Remove the cover -arrow- and open the vent plug underneath.

Scheme 83

Scheme 83
Scheme 83

Open the bleeder screw -arrow- on the fuel cooler.

Scheme 84

Scheme 84
Scheme 84

Press the --> button until the following display appears

Scheme 85

Scheme 85
Scheme 85
  1. Fuel cooler pump -V166

To activate, press the --> button.

  1. The fuel cooler pump is controlled in intervals.

Close the vent plug as soon as coolant comes out without any bubbles; repeat "output diagnostic test mode" if necessary.

All Vehicles

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

Close coolant reservoir cap.

Start the engine.

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

Press the ECON/ON/OFF button to turn off the A/C compressor.

  1. The LED inside the button must 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 engine at 2000 RPM for 1 minute.

Turn off engine and allow it to cool off.

Install the noise insulation. Refer to Removal and Installation .

Scheme 86

Scheme 86: CHECK THE COOLANT LEVEL
Scheme 86: CHECK THE COOLANT LEVEL
  1. Coolant level must be at MAX-marking -arrow- with engine cold.
  2. Coolant level may be above MAX marking with engine at operating temperature.

On a vehicle with air suspension, deactivate vehicle lift mode. Refer to General Information .

COOLANT HOSE CONNECTION DIAGRAM

WARNINGRisk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Arrows on coolant pipes and coolant hoses must line up across from each other.

Note. Blue = large coolant circuit. Brown = heating circuit. Green = fuel system coolant circuit. Orange = exhaust gas recirculation coolant circuit. Red = small coolant circuit.

Scheme 87

Scheme 87
Scheme 87
  1. Fuel System Cooler Change coolant after replacing
  2. Fuel Cooler Pump -V166
  3. Non-Return Valve The arrow points in the flow direction
  4. Radiator Change coolant after replacing
  5. Engine Coolant Temperature Sensor on Radiator -G83
  6. Bleeder Screw
  7. Coolant Thermostat For the exhaust gas recirculation coolant circuit
  8. Coolant Thermostat
  9. Exhaust Gas Recirculation (EGR) Cooler Pump -V400- In the exhaust gas recirculation coolant circuit
  10. Generator
  11. Engine Oil Cooler
  12. Cylinder Head Bank 1 (right) Change coolant after replacing
  13. Coolant Reservoir
  14. Coolant Reservoir Cap Pressure relief valve, checking «PRESSURE RELIEF VALVE IN CAP, CHECKING»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__pressure-relief-valve-in-cap-checking)
  15. Engine Coolant Temperature Sensor -G62
  16. Bleeder Screw
  17. Auxiliary Cooler for the Exhaust Gas Recirculation (EGR)
  18. Cooler for Exhaust Gas Recirculation (EGR)
  19. By-Pass Valve for the Exhaust Gas Recirculation (EGR) Cooler
  20. From Heat Exchanger for Heater Unit
  21. To Heat Exchanger for Heater Unit
  22. Cylinder Head Bank 2 (left) Change coolant after replacing
  23. Fuel Cooler On the fuel filter Only vehicles built through 05.10
  24. Bleeder Screw Only vehicles built through 05.10
  25. Coolant Thermostat For the exhaust gas recirculation coolant circuit With exhaust gas recirculation (EGR) motor -V338
  26. Coolant Pump Only vehicles built through 05.10
  27. Bleeder Screw Only vehicles built through 05.10

Scheme 88

Scheme 88: COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW
Scheme 88: COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW
  1. Coolant Thermostat with Connection Removing and installing, refer to «CONNECTING PIECE WITH COOLANT THERMOSTAT»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__connecting-piece-with-coolant-thermostat)
  2. Coolant Hose From the radiator at the bottom and on the right side
  3. Bolt 9 Nm
  4. Coolant Hose To the left top coolant pipe
  5. Coolant Hose From the Exhaust Gas Recirculation Cooler Pump -V400
  6. Coolant Thermostat for the Exhaust Gas Recirculation with Connection Removing and installing, refer to «EXHAUST GAS RECIRCULATION COOLANT THERMOSTAT AND CONNECTION»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__exhaust-gas-recirculation-coolant-thermostat-and)
  7. O-ring Replace
  8. Seal Replace
  9. Bolt 9 Nm
  10. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pump)
  11. Bolt Tightening specification and sequence (Scheme 89)
  12. Ribbed Belt Pulley for Coolant Pump Installation position: the word "vorne" (front) faces the direction of travel
  13. Bolt 23 Nm

Scheme 89

Scheme 89
Scheme 89

Tighten the coolant pump bolts -arrow- in a diagonal sequence in stages to 9 Nm.

Scheme 90

Scheme 90
Scheme 90

Tighten the fuel cooler pump bracket bolt -arrow- to 23 Nm.

Scheme 91

Scheme 91: Exhaust Gas Recirculation Cooler Pump -V400- OVERVIEW
Scheme 91: Exhaust Gas Recirculation Cooler Pump -V400- OVERVIEW
  1. Coolant Hose To coolant thermostat
  2. Exhaust Gas Recirculation (EGR) Cooler Pump -V400- Removing and installing, refer to «EGR COOLER PUMP»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__egr-cooler-pump)
  3. Bolt Tightening specifications, refer to "M8 Bolts" in numbered list under «CYLINDER HEAD OVERVIEW»(/audi/q7/4l-2009-2015/remont/mechanical/#30l-cylinder-head-valvetrain-engine-codes-cata__cylinder-head-overview)
  4. Bolt 2.7 Nm
  5. Engine Lifting Eye
  6. Coolant hose To cooler for exhaust gas recirculation

COOLANT PIPES OVERVIEW

Part 1

Scheme 92

Scheme 92: COOLANT PIPES OVERVIEW
Scheme 92: COOLANT PIPES OVERVIEW
  1. O-ring Replace
  2. Nut 9 Nm
  3. Right Coolant Pipe Removing and installing, refer to «RIGHT COOLANT PIPE»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__right-coolant-pipe)
  4. Bolt 23 Nm
  5. Seal Replace
  6. Bleeder Screw 9 Nm
  7. Engine Lifting Eye
  8. Bolt 9 Nm
  9. Bolt 9 Nm
  10. Connection Piece
  11. O-ring Replace
  12. Upper Right Coolant Pipe Removing and installing, refer to «UPPER RIGHT COOLANT PIPE»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__upper-right-coolant-pipe)
  13. Bolt Tightening specifications, refer to «Description and Operation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
  14. Engine Cover Bolt Tightening specifications, refer to «FASTENER TIGHTENING SPECIFICATIONS»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata__fastener-tightening-specifications)
  15. O-ring Replace
  16. Connecting Piece
  17. Bolt 9 Nm
  18. Coolant Temperature Sensor -G62- 2 Nm Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__engine-coolant-temperature-sensor)
  19. O-rings Replace Note the different diameter
  20. Rear Coolant Pipe Removing and installing, refer to «REAR COOLANT PIPE»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__rear-coolant-pipe)
  21. Bolt 9 Nm
  22. O-ring Replace
  23. Bolt 9 Nm
  24. Left Rear Coolant Pipe on the Exhaust Gas Recirculation Auxiliary Cooler Removing and installing, refer to «LEFT REAR COOLANT PIPE ON EXHAUST GAS RECIRCULATION AUXILIARY COOLER»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__left-rear-coolant-pipe-on-exhaust)
  25. Bolt 9 Nm
  26. O-ring Replace
  27. Left Rear Coolant Pipe on the Transmission Removing and installing, refer to «LEFT REAR COOLANT PIPE ON TRANSMISSION»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__left-rear-coolant-pipe-on-transmission)
  28. Bolt 9 Nm
  29. Bolt 9 Nm
  30. Upper Coolant Pipe Removing and installing, refer to «UPPER COOLANT PIPE»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__upper-coolant-pipe)
  31. Nut 9 Nm
  32. O-ring Replace

Part 2

Scheme 93

Scheme 93
Scheme 93
  1. Seals Replace
  2. Banjo Bolt 15.5 Nm
  3. Bolt 9 Nm
  4. Coolant Pipe To the cylinder heads
  5. Coolant Hose From the exhaust gas recirculation coolant thermostat
  6. Seal Replace
  7. Bleeder Screw 9 Nm
  8. Engine Cover Bolt Tightening specifications, refer to «Removal and Installation»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-diesel-fuel-injection-engine-codes-cata)
  9. Upper Left Coolant Pipe Removing and installing - vehicles built through 05.10, refer to «LEFT UPPER COOLANT PIPE, VEHICLES BUILT THROUGH 05.10»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__left-upper-coolant-pipe-vehicles-built) Removing and installing - vehicles built from 06.10, refer to «LEFT UPPER COOLANT PIPE, VEHICLES BUILT FROM 05.10»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__left-upper-coolant-pipe-vehicles-built)
  10. Bolt 9 Nm
  11. Left Rear Coolant Pipe Removing and installing, refer to «LEFT REAR COOLANT PIPE»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__left-rear-coolant-pipe)
  12. Bolt 9 Nm
  13. Bolt 9 Nm
  14. Bolt 9 Nm
  15. Left Coolant Pipe Removing and installing, refer to «LEFT COOLANT PIPE»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__left-coolant-pipe)
  16. Bolt 9 Nm
  17. O-ring Replace

RADIATOR OVERVIEW

WARNINGRisk of injury from coolant fan starting by itself. Before working in fan shroud area, disconnect electrical connectors.

Vehicles Built through 05.10

Scheme 94

Scheme 94
Scheme 94
  1. Hydraulic Oil Cooling Line For power steering
  2. Condenser For air conditioning system
  3. Retaining Clips Make sure it is secure
  4. Coolant Pipe For the fuel system coolant circuit
  5. Bolt 8 Nm
  6. Coolant Hose For the fuel system coolant circuit
  7. Bolt 8 Nm
  8. Sleeve
  9. Grommet
  10. Fuel System Cooler Removing and installing, refer to «FUEL SYSTEM COOLER, VEHICLES BUILT THROUGH 05.10»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__fuel-system-cooler-vehicles-built-through) Change coolant after replacing
  11. Bleeder Screw 1.5 to 3 Nm
  12. Cover
  13. Radiator Removing and installing, refer to «RADIATOR»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__radiator) Change coolant after replacing
  14. Grommet
  15. Bolt 5.5 Nm
  16. O-ring Replace
  17. Coolant Hose Lift the retaining clamp to remove Connect to the radiator (Scheme 96)
  18. Clip Make sure it is secure
  19. Engine Coolant Temperature Sensor on Radiator -G83- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__engine-coolant-temperature-sensor-on-radiator)
  20. O-ring Replace
  21. Coolant Hose
  22. Coolant Hose Lift the retaining clamp to remove Connect to the radiator (Scheme 96)
  23. O-ring Replace
  24. Rubber Buffer
  25. Retainer For the cooler mount
  26. Washer
  27. Clip Make sure it is secure
  28. ATF Cooler For automatic transmission Removing and installing, refer to «RADIATOR»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__radiator) Change coolant after replacing
  29. Bolt 8 Nm
  30. Air Duct Only the left air duct is shown in the illustration
  31. Bolt 2.5 Nm
  32. Bolt 8 Nm

Vehicles Built from 06.10

Scheme 95

Scheme 95
Scheme 95
  1. Hydraulic Oil Cooling Line For power steering
  2. Condenser For air conditioning system
  3. Retaining Clips Make sure it is secure
  4. Radiator Removing and installing, refer to «RADIATOR»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__radiator) Change coolant after replacing
  5. Grommet
  6. Bolt 5.5 Nm
  7. O-ring Replace
  8. Coolant Hose Lift the retaining clamp to remove Connect to the radiator (Scheme 96)
  9. Clip Make sure it is secure
  10. Engine Coolant Temperature Sensor (on Radiator) -G83- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__engine-coolant-temperature-sensor-on-radiator)
  11. O-ring Replace
  12. Coolant hose
  13. Coolant Hose Lift the retaining clamp to remove Connect to the radiator (Scheme 96)
  14. O-ring Replace
  15. Rubber Buffer
  16. Retainer For the cooler mount
  17. Washer
  18. Clip Make sure it is secure
  19. ATF Cooler For automatic transmission Removing and installing, refer to «RADIATOR»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__radiator) Change coolant after replacing
  20. Bolt 8 Nm
  21. Air Duct Only the left air duct is shown in the illustration
  22. Bolt 2.5 Nm
  23. Bolt 8 Nm

Scheme 96

Scheme 96
Scheme 96

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.

Scheme 97

Scheme 97: FAN SHROUD AND COOLANT FAN OVERVIEW
Scheme 97: FAN SHROUD AND COOLANT FAN OVERVIEW
  1. Coolant Fan -V7- with Coolant Fan Control Module -J293- Removing and installing, refer to «COOLANT FAN»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-fan)
  2. Coolant Fan 2 -V177- with Coolant Fan Control Module 2 -J671- Removing and installing, refer to «COOLANT FAN»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-fan)
  3. Fan Rib Removing and installing - vehicles built through 05.10, refer to «FAN SHROUD, VEHICLES BUILT THROUGH 05.10»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__fan-shroud-vehicles-built-through-0510) Removing and installing - vehicles built from 06.10, refer to «FAN SHROUD, VEHICLES BUILT FROM 06.10»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__fan-shroud-vehicles-built-from-0610)
  4. Bolt 10 Nm
  5. Bolt 10 Nm

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Air Duct2.5
Bleeder Screw9
Coolant Line to the Cylinder Heads (3)
Bolt9
Banjo Bolt15.5
Condenser8
Connecting Piece9
Coolant Fan with Coolant Fan Control (FC) Control Module10
Coolant Pipe for the Fuel System Coolant Circuit8
Coolant Temperature Sensor2
Coolant Thermostat for the Exhaust Gas Recirculation with Connection9
Coolant Thermostat with Connection9
Engine Lifting Eye (1)
2.7
23
Engine Lifting Eye (2)23
Fuel System Cooler
Bleeder Screw1.5 to 3
Bolt8
Hydraulic Oil Cooling Pipe8
Left Coolant Pipe9
Left Rear Coolant Pipe9
Left Rear Coolant Pipe on the Exhaust Gas Recirculation Auxiliary Cooler9
Left Rear Coolant Pipe on the Transmission9
Radiator5.5
Rear Coolant Pipe9
Ribbed Belt Pulley for Coolant Pump23
Right Coolant Pipe (2)
Nut9
Bolt23
Bolt9
Upper Coolant Pipe, Nut9
Upper Left Coolant Pipe9
Upper Right Coolant Pipe9
(1) For bolt tightening clarification, refer to Exhaust Gas Recirculation Cooler Pump -V400- OVERVIEW and see items -3 and 4- (2) For bolt tightening clarification, refer to COOLANT PIPES OVERVIEW Part 1 and see items -2, 4 and 8- (3) For bolt tightening clarification, refer to COOLANT PIPES OVERVIEW Part 2 and see items -2 and 3
(1)For bolt tightening clarification, refer to Exhaust Gas Recirculation Cooler Pump -V400- OVERVIEW and see items -3 and 4
(2)For bolt tightening clarification, refer to COOLANT PIPES OVERVIEW Part 1 and see items -2, 4 and 8
(3)For bolt tightening clarification, refer to COOLANT PIPES OVERVIEW Part 2 and see items -2 and 3

Coolant Pump - Tightening Specification and Sequence

Tighten the coolant pump bolts -arrow- in a diagonal sequence in stages to 9 Nm.

Vehicles Built through 05.10: Fuel Cooler Pump -V166-, Tightening Specifications

Tighten the fuel cooler pump bracket bolt -arrow- to 23 Nm.

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.
WARNINGRisk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

Open the coolant reservoir cap.

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

Scheme 98

Scheme 98
Scheme 98

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

If pressure falls, search for leaks and correct problem.

PRESSURE RELIEF VALVE IN CAP, CHECKING

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

Scheme 99

Scheme 99: PRESSURE RELIEF VALVE IN CAP, CHECKING
Scheme 99: PRESSURE RELIEF VALVE IN CAP, CHECKING

Generate pressure with cooling system tester hand pump.

  1. The pressure release valve must open at 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. Spanner Wrench 3212

Removing

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

Remove the ribbed belt from the tensioning element. Refer to RIBBED BELT .

Tilt the toothed belt guard forward -arrows- and disengage the pins on the underside of the guard.

Scheme 100

Scheme 100
Scheme 100

Note. The toothed belt guard is shown with the intake manifold upper section removed.

Using a 3212 as a counterholder, remove the bolts -arrows- and remove the coolant pump ribbed belt pulley.

Scheme 101

Scheme 101
Scheme 101

Remove the bolts and remove the coolant pump -arrow-.

Installing

Install in reverse order of removal. Note the following

Clean the sealing surface.

Tighten the coolant pump bolts. (Scheme 89)

Install the ribbed belt. Refer to RIBBED BELT .

Fill with coolant FILLING .

CONNECTING PIECE WITH COOLANT THERMOSTAT

Special tools and workshop equipment required

  1. Hose Clip Pliers VAS 6362

Removing

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

Remove the ribbed belt from the tensioning element. Refer to RIBBED BELT .

Remove the bolt -1- and disconnect the exhaust gas recirculation (EGR) coolant thermostat and connection from the connection.

Scheme 102

Scheme 102
Scheme 102

Note. Ignore -2 and 3-.

Remove the coolant hose; to do this, loosen the hose clamp -1-.

Scheme 103

Scheme 103
Scheme 103

Remove the bolts -arrows- and the coolant thermostat with the connection.

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata) .

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

Clean the sealing surface.

Install the ribbed belt. Refer to RIBBED BELT .

Fill with coolant FILLING .

EXHAUST GAS RECIRCULATION COOLANT THERMOSTAT AND CONNECTION

Removing

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

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

Remove the bolt -1-.

Loosen the clamps -2- and -3- and remove the exhaust gas recirculation coolant thermostat from the connection and from the coolant hoses.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata) .

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

Clean the sealing surface.

Fill with coolant FILLING .

FUEL COOLER PUMP, VEHICLES BUILT THROUGH 05.10

Special tools and workshop equipment required

  1. Hose Clamps Up to 25 mm Dia. 3094
  2. Hose Clip Pliers VAS 6362

Removing

On a vehicle with air suspension, activate vehicle lift mode. Refer to General Information .

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

Disconnect the connector -1-.

Scheme 104

Scheme 104
Scheme 104

Loosen the hose clamps -3- and -4- and remove the 3094.

Remove the bolt -2- and the fuel cooler pump -V166-.

Installing

Install in reverse order of removal. Note the following

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

Tighten the fuel cooler pump to the longitudinal member. (Scheme 90)

Check the coolant level CHECK THE COOLANT LEVEL .

Install the noise insulation. Refer to Removal and Installation .

On a vehicle with air suspension, deactivate vehicle lift mode. Refer to General Information .

EGR COOLER PUMP

Removing

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

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

Disconnect the connector -2-.

Scheme 105

Scheme 105
Scheme 105

Remove the bolts -1-.

Remove the coolant hoses, to do this, loosen the hose clamps -arrows-.

Remove the exhaust gas recirculation (EGR) cooler pump -V400- with the engine lifting eye.

Remove the bolts -arrows- and remove the exhaust gas recirculation (EGR) cooler pump from the engine lift eyelet.

Scheme 106

Scheme 106
Scheme 106

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «Exhaust Gas Recirculation Cooler Pump -V400- OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata) .

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

Fill with coolant FILLING .

ENGINE COOLANT TEMPERATURE SENSOR

Removing

  1. Engine cold.

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

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Remove the air guide hose by loosening the hose clamps -arrows-.

Scheme 107

Scheme 107
Scheme 107

Disconnect electrical connector -arrow-.

Scheme 108

Scheme 108
Scheme 108

Remove the engine coolant temperature (ECT) sensor -G62-.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

Note. Replace O-rings. To prevent coolant loss, immediately turn the new engine coolant temperature (ECT) sensor into the thread. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model.

Check the coolant level CHECK THE COOLANT LEVEL .

ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR

Removing

  1. Engine cold.

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

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Note. Lay a cloth below to catch escaping coolant.

Vehicles Built through 05.10

Disconnect the connector -2-.

Remove the clamp and remove the engine coolant temperature (ECT) sensor on radiator -G83-.

Note. Ignore -1-.

Vehicles Built from 06.10

Disconnect the connector -3-.

Remove the retaining clip -2- and the engine coolant temperature (ECT) sensor -G83-.

Note. Ignore -1-.

Installing

Install in reverse order of removal. Note the following

Note. Replace O-ring. Insert the new engine coolant temperature (ECT) sensor -G83- immediately in the connection to prevent coolant loss.

Check the coolant level CHECK THE COOLANT LEVEL .

UPPER COOLANT PIPE

Removing

Remove the oil cooler. Refer to ENGINE OIL COOLER .

Remove the coolant hose; to do this, loosen the hose clamp -2-.

Scheme 109

Scheme 109: UPPER COOLANT PIPE
Scheme 109: UPPER COOLANT PIPE

Note. Ignore -1- and -arrow-.

Remove the front coolant pipe from cylinder block.

Installing

Install in reverse order of removal. Note the following

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

Clean and/or smooth the sealing surfaces of the O-rings.

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

Install the oil cooler. Refer to ENGINE OIL COOLER .

Fill with coolant FILLING .

LEFT COOLANT PIPE

Special tools and workshop equipment required

  1. Spanner Wrench 3212
  2. Drip Tray VAS 6208
  3. Hose Clip Pliers VAS 6362

Removing

Remove air conditioner (A/C) compressor. Refer to Removal and Installation .

Disconnect the connector -3-.

Scheme 110

Scheme 110
Scheme 110

Remove the bolts -1- and -2-, remove the throttle valve control module -J338- from the intake tube.

Using a 3212 as a counterholder, remove the bolts -arrows- and remove the power steering pump ribbed belt pulley.

Scheme 111

Scheme 111
Scheme 111

Remove the bolts -1- and -2-.

Scheme 112

Scheme 112
Scheme 112

Remove the power steering pump and tie it upward.

Remove the bolt -2- for the oil dipstick guide tube.

Scheme 113

Scheme 113
Scheme 113

Remove the ribbed belt tensioning element bolt -1-.

WARNINGRisk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.

Open the coolant reservoir cap.

Place the VAS 6208 under engine.

Scheme 114

Scheme 114
Scheme 114

Remove the coolant hose from the left coolant pipe by loosening the hose clamp -1- and letting the coolant drain out.

Remove the bolts -4- and -arrows- and remove the accessory assembly bracket.

Loosen the clamp -3- and remove the coolant hose from the left coolant pipe.

Remove the bolt -2- and remove the left coolant pipe from the bracket.

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

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

Clean or smooth the seal and O-ring sealing surfaces.

Coat the seal and O-ring with coolant and then mount them on the coolant pipe.

Install the accessory assembly bracket and ribbed belt tensioning element. Refer to RIBBED BELT DRIVE OVERVIEW .

Install oil dipstick guide tube. Refer to UPPER OIL PAN OVERVIEW .

Install the power steering pump. Refer to Removal and Installation .

Install throttle valve control module -J338-. Refer to Description and Operation .

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

Fill with coolant FILLING .

LEFT REAR COOLANT PIPE ON TRANSMISSION

Removing

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

Remove the primary catalytic converter. Refer to PRIMARY CATALYTIC CONVERTER .

Free up the coolant hoses -arrow-.

Scheme 115

Scheme 115: LEFT REAR COOLANT PIPE ON TRANSMISSION
Scheme 115: LEFT REAR COOLANT PIPE ON TRANSMISSION

Loosen the hose clamp -2- and lift clamp -4- to remove the coolant hoses.

Scheme 116

Scheme 116
Scheme 116

Free up the transmission vent hose -arrow-.

Remove the bolts -1- and -3- ; then remove the left coolant pipe on the back of the transmission and the coolant hoses.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

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

Connect the coolant hose to the coupling. (Scheme 96)

Install primary catalytic converter. Refer to PRIMARY CATALYTIC CONVERTER .

Fill with coolant FILLING .

LEFT REAR COOLANT PIPE

Special tools and workshop equipment required

  1. Hose Clip Pliers VAS 6362

Removing

Remove the left intermediate pipe. Refer to LEFT INTERMEDIATE PIPE .

Remove exhaust gas recirculation (EGR) cooler switch-over valve 2 -N381- -3-.

Scheme 117

Scheme 117
Scheme 117

Remove the bolts -arrows-.

Remove the left rear coolant pipe from the coolant hoses by loosening the hose clamps -1- and -2-.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

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

Install the left intermediate pipe. Refer to LEFT INTERMEDIATE PIPE .

Fill with coolant FILLING .

LEFT REAR COOLANT PIPE ON EXHAUST GAS RECIRCULATION AUXILIARY COOLER

Special tools and workshop equipment required

  1. Hose Clip Pliers VAS 6362

Removing

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

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Remove the bolt -1-.

Scheme 118

Scheme 118
Scheme 118

Remove the left rear coolant pipe from the exhaust gas recirculation auxiliary cooler.

Loosen the clamp -arrow- and remove the coolant hose.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

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

Clean and/or smooth the sealing surfaces of the O-rings.

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

Fill with coolant FILLING .

LEFT UPPER COOLANT PIPE, VEHICLES BUILT THROUGH 05.10

Removing

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

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Remove the exhaust gas recirculation (EGR) cooler switch-over valve -N345- -1- from the bracket.

Scheme 119

Scheme 119
Scheme 119

Remove the bolt -4- and the engine cover bolts -2-.

Free up the wiring harness -3- on the top of the coolant pipe on the left side.

Loosen the clamps -arrows- and remove the left upper coolant pipe.

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

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

Fill with coolant FILLING .

LEFT UPPER COOLANT PIPE, VEHICLES BUILT FROM 05.10

Removing

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

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Remove the exhaust gas recirculation cooler switch-over valve -N345- -1- from the bracket.

Scheme 120

Scheme 120
Scheme 120

Remove the bolts -4- and the engine cover bolts -2-.

Free up the wiring harness -3- on the top of the coolant pipe on the left side.

Loosen the clamps -arrows- and remove the left upper coolant pipe.

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

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

Fill with coolant FILLING .

RIGHT COOLANT PIPE

Special tools and workshop equipment required

  1. Engine Support Bridge 10-222 A
  2. Adapter 10-222 A /22
  3. Spanner Wrench 3212

Removing

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

Remove the generator. Refer to GENERATOR, AIR COOLED or refer to GENERATOR, GENERATION II, AIR-COOLED .

Scheme 121

Scheme 121
Scheme 121

Remove the exhaust gas recirculation (EGR) cooler pump -V400-. Refer to EGR COOLER PUMP .

Remove the bolt -1- and remove the exhaust gas recirculation coolant thermostat and connection from the thermostat and connection.

Note. Ignore -2 and 3-.

Disconnect the starter connector -2-.

Scheme 122

Scheme 122
Scheme 122

Remove the nut -1- and then remove the B+ wire form the threaded pin on the starter.

Pull the cover over the radiator -arrows-, to do this, disconnect the lower coolant hose.

Scheme 123

Scheme 123
Scheme 123

Attach the 10-222 A onto bolted fender edge.

Scheme 124

Scheme 124
Scheme 124
  1. The spindle is positioned forward.

Attach the spindle from the engine support bridge to the right rear engine lifting eyelet.

Pre-tension the engine slightly using the engine support bridge spindles.

Remove the nut -1- on the right longitudinal member and disconnect the ground (GND) connection.

Scheme 125

Scheme 125
Scheme 125

Remove the bolts and nuts -1 through 5- and remove the right engine support upward.

Scheme 126

Scheme 126
Scheme 126

Using a 3212 as a counterholder, remove the bolts -arrows- and remove the coolant pump ribbed belt pulley.

Remove the bolt -1-.

Scheme 127

Scheme 127
Scheme 127

Remove the coolant hose -arrow- from the right coolant pipe by lifting the retaining clamp.

Remove the bolt -1- and nut -2-.

Scheme 128

Scheme 128
Scheme 128

Remove the right coolant pipe forward from the cylinder block.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview), see scheme 81.

Note. Replace O-rings. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model.

Clean and/or smooth the sealing surfaces of the O-rings.

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

Connect the coolant hoses with the connector coupling. (Scheme 96)

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

Install the engine support and engine mount. Refer to SUBFRAME ASSEMBLY OVERVIEW .

Attach the B+ wire to the starter. Refer to GENERATOR, AIR COOLED or refer to GENERATOR, GENERATION II, AIR-COOLED .

Install the exhaust gas recirculation coolant thermostat and connection. Refer to EXHAUST GAS RECIRCULATION COOLANT THERMOSTAT AND CONNECTION .

Install the exhaust gas recirculation (EGR) cooler pump -V400-. Refer to EGR COOLER PUMP .

Install the generator. Refer to GENERATOR, AIR COOLED or refer to GENERATOR, GENERATION II, AIR-COOLED .

Fill with coolant FILLING .

UPPER RIGHT COOLANT PIPE

Special tools and workshop equipment required

  1. Hose Clamps Up to 25 mm Dia. 3094

Removing

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

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

Scheme 129

Scheme 129
Scheme 129

Vehicles Built through 05.10

Disconnect the connector -3- on the intake flap motor -V157-.

Scheme 130

Scheme 130
Scheme 130

Remove the bolts -4- and move the intake flap motor with the connecting rod -1- still attached to the side.

Note. The connecting is not removed to avoid damage to the intake flap motor. Ignore -2-.

Remove the bolt -1- and banjo bolt -3- for the oil supply line on the turbocharger.

Scheme 131

Scheme 131
Scheme 131

Move the oil supply line to the side.

Note. Ignore -2-.

All Vehicles

Disconnect the glow plug connectors for cylinders "1" and "2".

Free up the wiring harness on the right upper coolant pipe.

Disconnect and remove the coolant hoses and the 3094, to do this, loosen the hose clamps -arrows-.

Scheme 132

Scheme 132
Scheme 132

Remove the right upper coolant pipe.

Note. Ignore -1-.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

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

Install the oil supply line. Refer to TURBOCHARGER OVERVIEW .

Intake flap motor and intake manifold upper section, installing. Refer to Removal and Installation .

Check the coolant level. Refer to CHECK THE COOLANT LEVEL .

REAR COOLANT PIPE

Special tools and workshop equipment required

  1. Hose Clip Pliers VAS 6362

Removing

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

Remove the turbocharger. Refer to TURBOCHARGER .

Remove the bolts -1- and -3- ; then push the left coolant pipe on the back of the transmission downward.

Note. The installation location is shown with the engine removed. Ignore -2 and 4- and -arrows-.

Remove the bolt -arrow- on the preliminary catalytic converter strap.

Scheme 133

Scheme 133
Scheme 133

Disconnect the electrical connector -4- on the engine coolant temperature (ECT) sensor -G62-.

Scheme 134

Scheme 134
Scheme 134

Remove the bolts -1- and -2- and remove the rear coolant pipe from the exhaust gas recirculation cooler.

Loosen the clamp -3- and remove the rear coolant pipe.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__coolant-pipes-overview) .

Note. Replace O-ring. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model.

Clean and/or smooth the sealing surfaces of the O-rings.

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

Install the left coolant pipe to the back of the transmission. Refer to COOLANT PIPES OVERVIEW .

Install the turbocharger. Refer to TURBOCHARGER .

Fill with coolant FILLING .

RADIATOR

Special tools and workshop equipment required

  1. Hose Clip Pliers VAS 6362

Removing

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

Remove air filter insert. Refer to Removal and Installation .

Scheme 135

Scheme 135
Scheme 135

Vehicles Built through 05.10

Remove the air duct hoses by loosening the hose clamps -1, 2 and 3-.

Scheme 136

Scheme 136
Scheme 136

Free up the coolant hose on the front air duct in the center.

Disconnect the connector -2- on the charge air pressure sensor -G31-.

Scheme 137

Scheme 137
Scheme 137

Remove the coolant hose by loosening the hose clamp -1-.

Remove the front air duct pipe in the center and the intake flap motor 2 -V275-.

Note. Ignore -3-.

Disconnect the connector -2-.

Scheme 138

Scheme 138
Scheme 138

Lift the clips -1-, loosen the clamp -3- and -4- and remove the air duct hoses.

Remove the lower air duct pipe.

All Vehicles

Disconnect the coolant hose from the radiator by raising the retaining clip -arrow-.

Scheme 139

Scheme 139
Scheme 139

Remove left and right radiator locking mechanism by pressing down against clamps -arrow-.

Scheme 140

Scheme 140
Scheme 140

Remove the bolts -2- on the left and right sides of the lock carrier.

Scheme 141

Scheme 141
Scheme 141

Disengage the cooler and move it toward the rear.

Note. Ignore -1-.

Remove the bolt -2- from the back of the radiator.

Scheme 142

Scheme 142
Scheme 142

Disengage power steering cooler -1- on climate control system condenser.

Note. The hydraulic hose lines remain connected.

Remove the bolt -1- from the back of the radiator.

Scheme 143

Scheme 143
Scheme 143

Remove the clips -2- and -3-.

Remove ATF cooler -4- from radiator.

Note. The ATF hose line remains connected.

Remove the bolt -3- on the back of the radiator.

Scheme 144

Scheme 144
Scheme 144

Remove the clips -2- and -4-.

CAUTIONThere is a risk of damaging the condenser and refrigerant lines and hoses. Do not stretch, kink or bend refrigerant lines and hoses.

Remove the A/C condenser -1- from the cooler with the refrigerant lines still connected.

Remove the radiator downward.

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «RADIATOR OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__radiator-overview) .

Note. If there are small impressions on the fins. Refer to COOLERS, CONDENSERS AND CHARGE AIR COOLERS . The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model.

Connect the coolant hoses with the connector coupling. (Scheme 96)

Install fan shroud. Refer to FAN SHROUD, VEHICLES BUILT THROUGH 05.10 .

Install air filter insert. Refer to Removal and Installation .

Install the air duct pipes with the connector coupling. (Scheme 145)

Scheme 145

Scheme 145
Scheme 145

Install the air duct hoses and screw-type clamps. (Scheme 146)

Scheme 146

Scheme 146
Scheme 146

Fill with coolant FILLING .

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

FUEL SYSTEM COOLER, VEHICLES BUILT THROUGH 05.10

Removing

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

Remove front bumper cover. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the left and right air ducts.

Scheme 147

Scheme 147: FUEL SYSTEM COOLER, VEHICLES BUILT THROUGH 05.10
Scheme 147: FUEL SYSTEM COOLER, VEHICLES BUILT THROUGH 05.10

Remove the bolts -2 through 5- ; then loosen the clamps -1- and -6- and remove the fuel cooling circuit cooler from the coolant hoses.

Scheme 148

Scheme 148
Scheme 148

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «RADIATOR OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata__radiator-overview) .

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

Install front bumper. Refer to Removal and Installation .

Fill with coolant FILLING .

FAN SHROUD, VEHICLES BUILT THROUGH 05.10

Removing

On a vehicle with air suspension, activate vehicle lift mode. Refer to General Information .

Switch off ignition and remove ignition key.

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Pull the cover over the radiator -arrows-, to do this disconnect the lower coolant hose.

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

Remove the bolts -arrows- for the lower air duct pipe.

Note. Ignore items -1 through 4-.

Open the clamp -arrow-, remove the air duct hose and move toward the back.

Scheme 149

Scheme 149
Scheme 149

Remove the bolts -2, 4 and 5-.

Scheme 150

Scheme 150
Scheme 150

Note. Ignore -1, 3 and 6-.

Free up the coolant hose on the upper air guide pipe

Scheme 151

Scheme 151
Scheme 151

Remove the bolts -1, 2 and 4-, then remove the upper air guide pipe from the charge air cooler and move it toward the back with the air guide hose -3- still connected.

WARNINGRisk of injury from coolant fan starting by itself. Before working in fan shroud area, disconnect electrical connectors.

Disconnect the connectors -1- and -2- and free up the electrical wires.

Scheme 152

Scheme 152
Scheme 152

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

Installing

Install in reverse order of removal. Note the following

Note. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model.

Press the fan shroud onto the radiator until it clicks into place.

Install the air duct pipes with the connector coupling. (Scheme 145)

Install the noise insulation. Refer to Removal and Installation .

On a vehicle with air suspension, deactivate vehicle lift mode. Refer to General Information .

FAN SHROUD, VEHICLES BUILT FROM 06.10

Removing

On a vehicle with air suspension, activate vehicle lift mode. Refer to General Information .

Switch off ignition and remove ignition key.

Carefully pull the engine cover -arrows- off the 4 bolts one after the other.

Pull cover over radiator -arrows-.

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

Lift the clip -1-, loosen the clamp -4- and remove the air guide hoses.

Scheme 153

Scheme 153
Scheme 153

Remove the bolts -2- and -3- and remove the lower air guide pipe.

Remove the bolts -2- and -3-.

Scheme 154

Scheme 154
Scheme 154

Loosen the clamps -1- and -4- and remove the air guide hoses.

Remove the air duct pipe downward.

Remove the air guide hose by loosening the hose clamps -arrows-.

Scheme 155

Scheme 155
Scheme 155

Disconnect the connector -1-.

Scheme 156

Scheme 156
Scheme 156

Remove the bolts -2 through 4- and then remove the air guide pipe from the charge air cooler.

Lift the clips -1-, loosen the hose clamps -2- and -3- and remove the air duct hoses.

Scheme 157

Scheme 157
Scheme 157
WARNINGRisk of injury from coolant fan starting by itself. Before working in fan shroud area, disconnect electrical connectors.

Disconnect the connectors -1 and 2- and free up the wires.

Press locking tabs at left and right on fan shroud -arrow- and at the same time, lift fan shroud out of engine compartment.

Installing

Install in reverse order of removal. Note the following

Install the air duct pipes with the connector coupling. (Scheme 145)

Press the fan shroud onto the radiator until it clicks into place.

COOLANT FAN

Removing

Remove fan shroud. Refer to FAN SHROUD, VEHICLES BUILT THROUGH 05.10 .

Free up electrical wires.

Remove bolts -1, 2, 3, 4, 8- and remove coolant fan 2 -V177- with coolant fan control module 2 -J671-.

Scheme 158

Scheme 158: COOLANT FAN
Scheme 158: COOLANT FAN

Remove bolts -5, 6, 7- and remove coolant fan -V7- with coolant fan control module -J293-.

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «FAN SHROUD AND COOLANT FAN OVERVIEW»(/audi/q7/4l-2009-2015/remont/cooling-fan/#30l-cooling-system-engine-codes-cata) .

Install fan shroud. Refer to FAN SHROUD, VEHICLES BUILT THROUGH 05.10 .

Scheme 159

Scheme 159: SPECIAL TOOLS
Scheme 159: SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 160

Scheme 160
Scheme 160

Scheme 161

Scheme 161
Scheme 161

Scheme 162

Scheme 162
Scheme 162

Scheme 163

Scheme 163
Scheme 163

Scheme 164

Scheme 164
Scheme 164

Scheme 165

Scheme 165
Scheme 165
  1. Adapter V.A.G 1274/8
  2. Adapter V.A.G 1274 Tester V.A.G 1274/10
  3. Drip Tray VAS 6208
  4. Cooling System Charge Unit VAS 6096
  5. Hose Clip Pliers VAS 6362
  6. Refractometer T10007
  7. Cooling System Tester V.A.G 1274 B
  8. Adapter V.A.G 1274/9
  9. Spanner Wrench 3212
  10. Hose Clamps Up to 25 mm Dia. 3094
  11. Engine Support Bridge 10-222 A
  12. Adapter 10-222 A /22

See also:
• General Information
• Removal and Installation
• CYLINDER HEAD OVERVIEW
• Description and Operation
• FASTENER TIGHTENING SPECIFICATIONS
• RIBBED BELT
• ENGINE OIL COOLER
• Removal and Installation
• RIBBED BELT DRIVE OVERVIEW
• UPPER OIL PAN OVERVIEW
• Removal and Installation
• PRIMARY CATALYTIC CONVERTER
• LEFT INTERMEDIATE PIPE
• GENERATOR, AIR COOLED
• GENERATOR, GENERATION II, AIR-COOLED
• SUBFRAME ASSEMBLY OVERVIEW
• TURBOCHARGER OVERVIEW
• TURBOCHARGER
• COOLERS, CONDENSERS AND CHARGE AIR COOLERS
• Removal and Installation
• AIR DUCT PIPES AND AIR DUCT HOSES OVERVIEW, VEHICLES BUILT THROUGH 05.10
• COOLANT PIPES OVERVIEW
• COOLANT MIXTURE RATIO
• PRESSURE RELIEF VALVE IN CAP, CHECKING
• CONNECTING PIECE WITH COOLANT THERMOSTAT
• EXHAUST GAS RECIRCULATION COOLANT THERMOSTAT AND CONNECTION
• COOLANT PUMP
• EGR COOLER PUMP
• RIGHT COOLANT PIPE
• UPPER RIGHT COOLANT PIPE
• ENGINE COOLANT TEMPERATURE SENSOR
• REAR COOLANT PIPE
• LEFT REAR COOLANT PIPE ON EXHAUST GAS RECIRCULATION AUXILIARY COOLER
• LEFT REAR COOLANT PIPE ON TRANSMISSION
• UPPER COOLANT PIPE
• LEFT UPPER COOLANT PIPE, VEHICLES BUILT THROUGH 05.10
• LEFT REAR COOLANT PIPE
• LEFT COOLANT PIPE
• FUEL SYSTEM COOLER, VEHICLES BUILT THROUGH 05.10
• RADIATOR
• ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR
• COOLANT FAN
• FAN SHROUD, VEHICLES BUILT THROUGH 05.10
• FAN SHROUD, VEHICLES BUILT FROM 06.10
• Exhaust Gas Recirculation Cooler Pump -V400- OVERVIEW
• COOLING SYSTEM, DRAINING AND FILLING
• FILLING
• RADIATOR OVERVIEW

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