4.2l - Cooling System - Engine Code(s): Caua (coupe) Audi S5 I

COOLANT, DRAINING AND FILLING

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Adapter V.A.G 1274/10
3. Cooling System Charge Unit VAS 6096
4. Drip Tray for VAS 6100 VAS 6208
5. Hose Clip Pliers VAS 6362
6. Refractometer T10007

DRAINING

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

Scheme 1

Remove the front noise insulation -1-. Refer to Description and Operation in Underbody Trim.

Scheme 2

Place VAS 6208 under the engine.

Remove the drain plug -arrow- on the front coolant hose and drain the coolant.

Scheme 3

Remove the drain plug -arrow- on the map controlled engine cooling thermostat -F265- and drain the coolant.

Scheme 4

FILLING

1. Tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) , «COOLANT PIPES OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) .
2. Ignition turned off

Note. The cooling system is filled year-round with a mixture of water and coolant additive. Mixture ratio COOLANT, DRAINING AND FILLING . 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 COOLANT, DRAINING AND FILLING prevents freezing and corrosion damage and calcium deposits. 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 for climatic reasons a greater frost protection is required, the amount of can be increased, but only up to 60% (frost protection to about -40 °C (-40 °F)), as otherwise frost protection is reduced again and cooling effectiveness is also reduced. Only use clean drinking water for mixing coolant. Only reuse drained coolant if the radiator, heater heat exchanger, cylinder head, cylinder head gasket or cylinder block were not replaced. Dirty coolant may not be used again. Use the T10007 to determine the level of freeze protection in the coolant system. Secure all hose connections with hose clamps of the same type as those equipped by the factory. Replace the gasket and O-ring.

COOLANT MIXTURE RATIO

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

Procedure

Install the drain plug -arrow- with a new O-ring on the map controlled engine cooling thermostat -F265-.

Install the front coolant pipe drain plug -arrow- with a new sealing.

Fill coolant reservoir on VAS 6096 with 15 liters of premixed coolant with the proper mixture ratio.

Scheme 5

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 the 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 6

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 the instrument display must remain in the green region, then 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 VAS 6096 form V.A.G 1274/8 on coolant reservoir.

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

Scheme 7

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

Scheme 8

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

Scheme 9

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 the cap on the coolant reservoir until it latches.

Start the engine.

Adjust the temperature for all zones to "HI".

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 engine at 2000 RPM for 1 minute.

Turn off the engine and allow it to cool off.

Install the front noise insulation. Refer to Description and Operation in Underbody Trim.

Check the coolant level.

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

COOLANT HOSE CONNECTION DIAGRAMS

Note. Secure all the 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.

Scheme 10

1. Radiator Change coolant after replacing
2. Engine Oil Cooler Change coolant after replacing
3. After-Run Coolant Pump -V51
4. Cylinder Head and Cylinder Block Change coolant after replacing
5. Throttle Valve Connection
6. Bleeder Hole Inside the coolant hose to the heater core for the heating
7. Heat Exchanger for Heater Unit Change coolant after replacing
8. Cover Pressure relief valve, checking «COOLING SYSTEM, CHECKING FOR LEAKS»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__cooling-system-checking-for-leaks)
9. Coolant Reservoir
10. Engine Coolant Temperature Sensor -G62
11. Map Controlled Engine Cooling Thermostat -F265
12. Coolant Pump

Scheme 11

1. Drain Plug 10 Nm
2. Seal Replace
3. Front Coolant Pipe Removing and installing, refer to «FRONT COOLANT PIPE»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__front-coolant-pipe)
4. Bolt 9 Nm
5. Seal Replace
6. Lower Left Coolant Pipe Removing and installing, refer to «LOWER LEFT COOLANT PIPE»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__lower-left-coolant-pipe)
7. Bolt 9 Nm
8. O-ring Replace
9. Coolant Connecting Piece Removing and installing, refer to «COOLANT CONNECTIONS»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)
10. Right Coolant Pipe Removing and installing, refer to «RIGHT COOLANT PIPE»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)
11. Bolt 9 Nm
12. Bolt 9 Nm
13. O-ring Replace
14. Coolant Hose
15. Rear Coolant Pipe Removing and installing, refer to «REAR COOLANT PIPE»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__rear-coolant-pipe)
16. Engine Coolant Temperature (ECT) Sensor -G62- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE (ECT) SENSOR -G62»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)
17. O-ring Replace
18. Retaining Clip
19. Bolt 9 Nm
20. O-ring Replace
21. Coolant Hose
22. Bolt 9 Nm
23. Nut 9 Nm
24. Bolts 9 Nm
25. Upper Left Coolant Pipe Removing and installing, refer to «UPPER LEFT COOLANT PIPE»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__upper-left-coolant-pipe)
26. Bolt 9 Nm
27. O-ring Replace
28. Bolt 9 Nm

Scheme 12

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 on to the coolant pipe -1- until you hear it engage.

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

Scheme 13

1. Seal Replace
2. Coolant Pump Housing Removing and installing, refer to «COOLANT PUMP»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__coolant-pump)
3. Bolt Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)
4. Front Coolant Pipe Removing and installing, refer to «FRONT COOLANT PIPE»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__front-coolant-pipe)
5. O-ring Replace
6. Seal Replace
7. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__coolant-pump)
8. O-ring Replace
9. Bolt 9 Nm
10. Driveshaft for Coolant Pump
11. O-ring Replace
12. Map Controlled Engine Cooling Thermostat -F265- Removing and installing, refer to «MAP CONTROLLED ENGINE COOLING THERMOSTAT -F265»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__map-controlled-engine-cooling-thermostat-f265) Thermostat opening data, refer to «THERMOSTAT OPENING DATA»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__thermostat-opening-data)
13. O-ring Replace
14. Drain Plug 4 Nm
15. Bolt 9 Nm

Scheme 14

Tighten the nut -1- for the after-run coolant pump to 5 Nm.

Note. Ignore -2- and -arrows-.

RADIATOR AND COOLANT FAN OVERVIEW

Scheme 15

1. Bolt 5 Nm
2. Bolt 5 Nm
3. Fan Shroud Removing and installing, refer to «FAN SHROUD»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)
4. Coolant Fan -V7- With coolant fan control module -J293- Removing and installing, refer to «COOLANT FAN»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)
5. Bolt 3.5 Nm
6. Rubber Buffer
7. Rubber Bushing For radiator
8. Coolant Hose Lift the retaining clamp to remove
9. O-ring Replace
10. Coolant Hose To the coolant reservoir
11. O-ring Replace
12. Radiator Removing and installing, refer to «RADIATOR»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) change coolant after replacing
13. Retaining Pin Disengage and remove using screwdriver
14. Rubber Buffer
15. Radiator Bracket
16. Bolt
17. O-ring Replace
18. Coolant Hose Lift the retaining clamp to remove
19. Coolant Fan 2 -V177- With coolant fan control module 2 -J671- Removing and installing, refer to «COOLANT FAN»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)

FASTENER TIGHTENING SPECIFICATIONS

AFTER-RUN COOLANT PUMP -V51-, TIGHTENING SPECIFICATIONS

Tighten the nut -1- for the after-run coolant pump to 5 Nm.

Note. Ignore -2- and -arrows-.

THERMOSTAT OPENING DATA

Note. The coolant thermostat cannot be checked with shop equipment.

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

Scheme 16

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

If pressure falls, search for leaks and correct problem.

Scheme 17

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.

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

AFTER-RUN COOLANT PUMP -V51

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094
2. Drip Tray for VAS 6100 VAS 6208
3. Hose Clip Pliers VAS 6362

REMOVING

Remove the front noise insulation -1-. Refer to Description and Operation in Underbody Trim.

Disconnect the coolant hoses -arrows- together with the 3094.

Disconnect the connector -2-.

Remove the nuts -1-.

Place the VAS 6208 under the after-run coolant pump.

Disconnect the coolant hoses and after-run coolant pump.

INSTALLING

Install in reverse order, paying attention to the following

1. Tightening specification (Scheme 14)

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

Install the front noise insulation. Refer to Description and Operation in Underbody Trim.

Check the coolant level COOLANT, DRAINING AND FILLING .

Scheme 18

Remove the engine cover -arrows-.

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove the plenum chamber bulkhead. Refer to Removal and Installation .

Remove the air duct -arrows-.

Scheme 19

Free up the fuel line and the line to the Evaporative Emission (EVAP) canister on the air guide pipe.

Scheme 20

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Disconnect the vacuum line -3- from the air guide pipe.

Lay aside air guide pipe with connected crankcase ventilation hose -2- by loosening hose clamp -4- and opening clips -arrows-.

Disconnect the vacuum line -1-.

Scheme 21

Remove the air filter housing and disconnect the electrical connector -2- on the rear side at the intake air switch-over valve -N335-.

Remove hose -3- from the secondary air system.

Remove the nuts -arrows- and move the vacuum pump -1- with the lines connected to the side.

Scheme 22

Remove the bolts -1 and 2- and remove the right coolant pipe from the coolant connection piece.

Scheme 23

Note. Ignore -arrow-.

Remove the bolts - 1 and 2- and loosen the hose clamp -arrow-.

Scheme 24

Disconnect the coolant connection pieces leading to the right side.

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) .

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory. When installing, bring all cable ties back to same positions.

Clean or smooth the sealing surface.

Install right coolant pipe. Refer to RIGHT COOLANT PIPE .

Install the air filter housing. Refer to Removal and Installation .

Install the plenum chamber bulkhead. Refer to Removal and Installation .

Install the vacuum pump. Refer to Removal and Installation .

Fill the coolant system COOLANT, DRAINING AND FILLING .

Remove fan shroud. Refer to FAN SHROUD .

Remove the left radiator fan bolts -arrows-.

Scheme 25

Free up the wiring harness and remove the left radiator fan.

Remove the right radiator fan bolts -arrows-.

Scheme 26

Free up the wiring harness.

Detach the radiator fan control module -1- from the fan shroud and remove the right radiator fan together with the control module.

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__radiator-and-coolant-fan-overview) .

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

Install fan shroud. refer to FAN SHROUD .

COOLANT PUMP

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6340

Scheme 27

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

Remove the map controlled engine cooling thermostat -F265- MAP CONTROLLED ENGINE COOLING THERMOSTAT -F265 .

Loosen the coolant hose clamp -1-.

Remove the bolts -arrows-.

Remove the coolant pump housing forward, being careful of the pump input shaft.

Note. Coolant hose can only be removed with coolant pump removed.

Remove the bolts -arrows- and remove the coolant pump -2- from the housing -1-.

Scheme 28

Scheme 29

1. For the correct tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) .

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

Insert the O-rings -1- and -3-.

Insert the coolant pump input shaft -2- into the oil pump mount as far as the stop.

Push the coolant pump into the brackets on the upper oil pan.

Note. To connect drive flange onto hex head of driveshaft, reach with the finger into the lower pipe connection of coolant pump and twist at impeller until coolant pump can be inserted completely.

Install in reverse order of removal paying attention to the following

Install the map controlled engine cooling thermostat. Refer to MAP CONTROLLED ENGINE COOLING THERMOSTAT -F265 .

Install front coolant pipe. Refer to FRONT COOLANT PIPE .

1. Engine cold.

Remove the engine cover -arrows-.

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

Disconnect the connector -1- from the ECT Sensor.

Scheme 30

Note. Use a cloth to catch any leaking coolant.

Remove retaining clip -2- and ECT Sensor.

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 COOLANT, DRAINING AND FILLING .

Remove the front noise insulation -1-. Refer to Description and Operation in Underbody Trim.

Disconnect the radiator fan electrical connectors -1 and 2-, to do this, push the clamp to the rear -arrow- and push the release down.

Scheme 31

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

Scheme 32

Remove the left and right bolts -1-.

Scheme 33

Note. Ignore -arrow-.

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

Scheme 34

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

Remove the bolts -arrows-.

Scheme 35

Remove the air filter housing air guide -1- on the intermediate flange -2-.

Release the clamps -arrow A- and tilt the power steering coolant hose -1- forward -arrow B-.

Scheme 36

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

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

Scheme 37

Note. The installation location is shown with the bumper cover removed.

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

Scheme 38

Pull the radiator on the left side toward the front -arrow B-, then push it to the left -arrow C- and finally pull the right side toward the front -arrow A-.

Scheme 39

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

Scheme 40

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__radiator-and-coolant-fan-overview) .

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

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

Install the lock carrier cover. Refer to Bumpers .

Install the front noise insulation. Refer to Description and Operation in Underbody Trim.

FRONT COOLANT PIPE

Special tools and workshop equipment required

1. Drip Tray for VAS 6100 VAS 6208

Scheme 41

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove fan shroud. Refer to FAN SHROUD .

Remove the bolts -arrows-.

Remove the front coolant pipe from the engine and from the coolant pump.

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) .

Note. Replace the O-rings.

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

Coat the O-rings with coolant and install them.

Install fan shroud. Refer to FAN SHROUD .

Fill the coolant system COOLANT, DRAINING AND FILLING .

LOWER LEFT COOLANT PIPE

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6340

Scheme 42

Remove the left exhaust manifold. Refer to LEFT EXHAUST MANIFOLD

Remove the bolts -1 and 2- and the lower left coolant pipe from the coolant hoses -arrows-.

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe)

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

Install the left exhaust manifold. Refer to LEFT EXHAUST MANIFOLD .

MAP CONTROLLED ENGINE COOLING THERMOSTAT -F265

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6362

Scheme 43

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove the bolt -1- as well as the nut -3- and remove the exhaust manifold brace -2-.

Disconnect the electrical connector -1- on the map controlled engine cooling thermostat.

Scheme 44

Disconnect the coolant hose by lifting the retaining clamps -2- and loosening the hose clamp -3-.

Remove the coolant hose -4-.

Remove the bolts -arrows- and the map controlled engine cooling thermostat

Scheme 45

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) .

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

Install the left lock carrier brace. Refer to Removal and Installation .

Fill the coolant system COOLANT, DRAINING AND FILLING .

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

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

Disconnect the coolant hose from the radiator, to do this, lift the retaining clip -2-.

Note. Ignore -1, 3 and 4-.

Disconnect the radiator fan electrical connectors -1 and 2-, to do this, push the clamp to the rear -arrow- and push the release down.

Disconnect the coolant hose from the radiator, to do this, lift the retaining clip -2-.

Scheme 46

Note. Ignore -1-.

Remove the bolts -arrows-.

Remove the air filter housing air guide -1- on the intermediate flange -2-.

Disconnect the coolant line -arrow- leading to the coolant overflow reservoir from the radiator by lifting the retaining clamp.

Scheme 47

Release the clamps -arrow A- and tilt the power steering coolant hose -1- forward -arrow B-.

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

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

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-.

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 -B arrows-.

Scheme 48

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.

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe__radiator-and-coolant-fan-overview) .

Note. If there are small impressions on the fins COOLERS AND CONDENSERS, INSTALLING .

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

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

Fill the coolant system. Refer to COOLANT, DRAINING AND FILLING .

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

REAR COOLANT PIPE

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6362

Remove the engine cover -arrows-.

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove the plenum chamber bulkhead. Refer to Removal and Installation .

Disconnect the secondary air hose -arrow- by pressing the release buttons.

Scheme 49

Disconnect the connector -2- from the Engine Coolant Temperature (ECT) sensor -G62-.

Scheme 50

Remove the coolant hose -3- by lifting the retaining clip.

Disconnect the coolant hoses -1 and 4- and loosen the hose clamp -5-.

Remove the bolts -arrows-.

Disconnect the rear coolant pipe leading to the left side from the coolant hose.

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) .

Note. Replace the O-rings. Secure all hose connections with hose clamps of the same type as those equipped by the factory. When installing, bring all cable ties back to same positions.

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

Coat the new O-ring with coolant.

Connect the coolant hose with the connector on the coolant pipe. (Scheme 12)

Install the plenum chamber bulkhead. Refer to Removal and Installation .

Fill the coolant system COOLANT, DRAINING AND FILLING .

Remove the right exhaust manifold. Refer to RIGHT EXHAUST MANIFOLD .

Remove the bolts -1 and 2-.

Disconnect the right coolant tube from the connection and from the coolant hose -arrow-.

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) .

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

Coat the new O-ring with coolant.

Install the right exhaust manifold. Refer to RIGHT EXHAUST MANIFOLD .

UPPER LEFT COOLANT PIPE

Special tools and workshop equipment required

1. Engine/Transmission Jack V.A.G 1383 A
2. Engine Bung Set VAS 6122
3. Hose Clip Pliers VAS 6340
4. Transmission Support T10337
5. Pry Lever - Rmv Outside Mirror 80 - 200

Remove the engine cover -arrows-.

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove the left catalytic converter. Refer to LEFT CATALYTIC CONVERTER

Vehicles with a Manual Transmission

Scheme 51

Remove the steering intermediate shaft from the steering gear and push them upward. Refer to Removal and Installation .

All Vehicles

Scheme 52

Remove the coolant hoses -1, 2 and 3- from the coolant reservoir.

Remove the bolts -arrows-.

Disconnect the connector on the engine coolant level warning switch -F66- and remove the coolant reservoir.

Remove the bolt -arrow- and disconnect the oil dipstick guide tube -1- from the top section of the oil pan.

Scheme 53

Remove the bolts -1 and 2- as well as the nuts -3-.

Scheme 54

Remove the coolant hoses -arrows-.

Remove the coolant hose -4- by lifting the retaining clip.

Vehicles with a Manual Transmission

Remove the upper left coolant pipe toward the rear.

Vehicles with Automatic Transmission

Scheme 55

Note. Catch any leaking ATF with a cloth.

Disconnect the ATF line -arrow-.

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

Note. Catch any leaking ATF with a cloth.

Remove the bolt -2-, and nut -3- and move the ATF line to the side.

Scheme 56

Mount the T10337 on the V.A.G 1383 A and attach it to the bottom of the transmission.

Scheme 57

Raise the transmission slightly.

Remove the bolts -arrows- on the tunnel crossmember.

Scheme 58

Lower the engine/transmission sub-assembly to dimension -a- using V.A.G 1383 A.

Scheme 59

1. Dimension -a- = 35 mm maximum.

Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the 80 - 200.

Scheme 60

Remove the clip and the selector lever cable from the transmission.

Note. Do not bend or kink the selector lever cable.

Remove the upper left coolant tube toward the rear.

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/s5/i-2007-2011/remont/cooling-fan/#42l-cooling-system-engine-codes-caua-coupe) .

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

Connect the coolant hose with the connector on the coolant pipe. (Scheme 12)

Install oil dipstick guide tube. Refer to CRANKSHAFT OVERVIEW .

Install selector lever cable. Refer to Removal and Installation .

Install the ATF lines. Refer to Description and Operation .

Install the left catalytic converter. Refer to LEFT CATALYTIC CONVERTER .

Install exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .

Attach the steering intermediate shaft to the steering gear. Refer to Removal and Installation .

Install the front crossmember. Refer to Description and Operation .

Scheme 61

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Adapter V.A.G 1274/10
3. Cooling System Charge Unit VAS 6096
4. Drip Tray for VAS 6100 VAS 6208
5. Hose Clip Pliers VAS 6362
6. Refractometer T10007

Special tools and workshop equipment required

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Hose Clamps Up to 25 mm Dia. 3094
2. Transmission Support T10337
3. Cooling System Tester V.A.G 1274 B
4. Adapter V.A.G 1274/9
5. Engine/Transmission Jack V.A.G 1383 A
6. Engine Bung Set VAS 6122
7. Hose Clip Pliers VAS 6340
8. Hose Clip Pliers VAS 6362
9. Not illustrated
10. Pry Lever - Rmv Outside Mirror 80 - 200

See also:
• Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• LEFT EXHAUST MANIFOLD
• COOLERS AND CONDENSERS, INSTALLING
• RIGHT EXHAUST MANIFOLD
• LEFT CATALYTIC CONVERTER
• Removal and Installation
• CRANKSHAFT OVERVIEW
• Removal and Installation
• EXHAUST SYSTEM, INSTALLING
• COOLANT PUMP AND COOLANT THERMOSTAT OVERVIEW
• COOLANT, DRAINING AND FILLING
• COOLING SYSTEM, CHECKING FOR LEAKS
• FRONT COOLANT PIPE
• LOWER LEFT COOLANT PIPE
• REAR COOLANT PIPE
• UPPER LEFT COOLANT PIPE
• COOLANT PUMP
• MAP CONTROLLED ENGINE COOLING THERMOSTAT -F265
• THERMOSTAT OPENING DATA
• RADIATOR AND COOLANT FAN OVERVIEW