Engine Cooling - 4.2l v8 5v - Art, Awn, Bbd Audi S6 C5

Cooling system components

Note. Hoses are secured with spring-type clamps. When repairing, only use the same type of spring-type clamps. Use VAG 1921 clamp pliers when installing spring-type clamps. Always replace O-rings at quick release connections if damaged or leaking. When installing coolant hoses, make sure they are free of stress and do not come in contact with other components. Observe markings on coolant hoses and connections.

Cooling system components, removing and installing

Note. Always replace seals and gaskets Draining and filling cooling system. See COOLING SYSTEM, DRAINING AND FILLING . Checking cooling system for leaks. See COOLING SYSTEM, CHECKING FOR LEAKS .

Note. The following list refers to items in (Scheme 10).

1. Rear coolant line
2. From heater core With bleeder valve
3. To heater core With bleeder valve
4. Return hose
5. Filler cap for coolant expansion tank Checking, «PRESSURE RELIEF VALVE IN FILLER CAP, CHECKING»(/audi/s6/c5-1999-2004/remont/cooling-fan/#engine-cooling-42l-v8-5v-art-awn-bbd)
6. Expansion tank
7. Filler hose
8. Thermostat Replacing, see «THERMOSTAT, REMOVING AND INSTALLING»(/audi/s6/c5-1999-2004/remont/cooling-fan/#engine-cooling-42l-v8-5v-art-awn-bbd) Starts to open at approx. 87° C (188° F) Fully open at approx. 102° C (215° F) Opening travel approx. 8 mm (0.3 in.)
9. Radiator
10. Bracket for coolant hoses
11. Coolant line From cylinder block to oil cooler
12. Oil cooler
13. Coolant line
14. Coolant line to oil cooler

Scheme 10

Coolant pump, removing and installing

Note. Always replace gaskets and seals Draining and filling cooling system. See COOLING SYSTEM, DRAINING AND FILLING .

Note. The following list refers to items in (Scheme 11).

1. Coolant pump Removing, see «REMOVING»(/audi/s6/c5-1999-2004/remont/cooling-fan/#engine-cooling-42l-v8-5v-art-awn-bbd__removing)
2. Gasket
3. 10 Nm (7 ft lb)

Scheme 11

Removing

1. Remove toothed (timing) belt. See «TOOTHED BELT, REMOVING AND INSTALLING»(ref-196260-S31667825522005100700000) .

Note. The vibration damper does not have to be unbolted or removed.

1. Remove toothed belt tensioning roller.
2. Remove coolant pump (9 Torx bolts).

Installing

1. Install coolant pump (9 Torx bolts).
2. Install toothed belt tensioning roller.
3. Install toothed belt. See «TOOTHED BELT, REMOVING AND INSTALLING»(ref-196260-S31667825522005100700000) .

Scheme 12

Tightening torques

TIGHTENING TORQUES: COOLANT (WATER) PUMP

The thermostat is located at the right front of the engine below the intake manifold.

Scheme 13

1. Drain coolant. See «COOLING SYSTEM, DRAINING AND FILLING»(/audi/s6/c5-1999-2004/remont/cooling-fan/#engine-cooling-42l-v8-5v-art-awn-bbd__cooling-system-draining-and-filling) .
2. Remove toothed belt from camshafts. See «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(ref-196260-S14760224332005100700000) .
3. Remove thermostat housing -arrows-.

Starts to open: 87° C (188° F)

Fully open: 102° C (215° F)

Opening travel: 8 mm (0.3 in.)

Position of thermostat

Note. Install with bleeder valve facing upward.

Scheme 14

1. Install thermostat housing.
2. Install toothed belt on camshafts. See «TOOTHED BELT, REMOVING FROM CAMSHAFT SPROCKETS»(ref-196260-S14760224332005100700000) .
3. Fill system with coolant. See «COOLING SYSTEM, DRAINING AND FILLING»(/audi/s6/c5-1999-2004/remont/cooling-fan/#engine-cooling-42l-v8-5v-art-awn-bbd__cooling-system-draining-and-filling) .

TIGHTENING TORQUES: THERMOSTAT HOUSING

Cooling system, draining and filling

Note. To prevent frost and corrosion damage and to raise the boiling point of the coolant, the specified coolant additive must be used in the cooling system at all times of the year. Recommended mixture ratio: 50:50 Capacity of cooling system: approx. 9.0 litres (approx. 3.5 gal) Do not use any other coolant than "G12"

COOLANT ADDITIVE SPECIFICATION

Draining

Scheme 15

Scheme 16

1. Remove noise insulation.
2. Remove grille on left side of bumper.
3. Install hose -1- to hose connection.
4. Place drip tray VAG 1306 under engine.
5. Drain coolant from radiator (bottom left) - arrow-.

Scheme 17

1. Open drain plugs -arrows- and drain coolant.

Filling

Note. The cooling system is filled all year round with a mixture of water and coolant additive (combined anti-freeze and corrosion protection agent).

Note. "G12" and coolant additives according to specification TL VW 774 D prevent frost and corrosion damage, stop scaling and raise the boiling point of the coolant. For these reasons the cooling system must be filled all year round with the correct anti-freeze and anti-corrosion additive. 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 to about -25°C (-13° F), in arctic climatic countries to about -35° C (-31° F). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The anti-freeze ratio must be at least 40% If greater frost protection is required in very cold climates, the amount of G12 can be increased, but only up to 60% (this gives frost protection to about -40° C or -40° F). Always replace coolant after replacing radiator, heater core, cylinder head or cylinder head gasket. Do not not reuse old coolant. Use special tool T40007 to check frost protection of coolant additive "G12" in cooling system.

Scheme 18

1. Close radiator drain plug and disconnect drain hose from hose connection.
2. Replace seals and install coolant drain plugs on engine block (left and right sides) - tightening torque 20 Nm (15 ft lb).
3. Switch ignition on.
4. Set air conditioner to high setting.
5. Switch ignition off.
6. Open bleed screw on heater core by about two full turns.
7. Fill with coolant. Squeezing top hose several times will help to force out air.
8. Start engine with air conditioner set at HI until coolant temperature gauge indicates just under 100° C (212° F). To warm up engine, run it at 2000 to 3000 rpm and accelerate briefly several times to 4000 to 5000 rpm.

1. Switch off engine, wait for about 5 to 10 minutes and then carefully open filler cap on expansion tank (system will be under pressure).
2. Top up coolant to max. mark.
3. Close filler cap on expansion tank.
4. Run engine and repeat topping up procedure as necessary.

Cooling system, checking for leaks

Note. Engine must be at operating temperature.

1. Install tester VW 1274 with adapter VW 1274/1 on expansion tank.
2. Build up pressure of approx. 1.0 bar with hand pump on tester. If pressure does not hold, locate and repair leaks.

Scheme 19

1. Install filler cap on tester.
2. Build up pressure with hand pump. Pressure relief valve must open at 1.2 to 1.5 bar.

Special tools and equipment

1. Wrench 3212
2. Open end 3312

Scheme 20

1. Remove intake air duct for air cleaner.
2. Remove front bumper See «FRONT BUMPER»(/audi/s6/c5-1999-2004/remont/exterior-body-panels/#bumper) .
3. Adjust lock carrier to service position. See «LOCK CARRIER, SERVICE POSITION»(/audi/s6/c5-1999-2004/remont/exterior-body-panels/#body-front__lock-carrier-service-position) .
4. Counter-hold viscous fan pulley with pin wrench 3212 and unscrew fan with open-end wrench 3312 (FAN HAS LEFT-HAND THREAD).
5. Remove viscous fan with outer ring.

Install viscous fan in reverse order of removal but note the following

Scheme 21

1. Install fan together with outer ring (FAN HAS LEFT-HAND THREAD).
2. Counter-hold fan pulley with pin wrench 3212 and tighten fan with open-end wrench 3312 and torque wrench 1331 (fan has left-hand thread).

TIGHTENING TORQUES: VISCOUS FAN

See also:
• FRONT BUMPER
• LOCK CARRIER, SERVICE POSITION
• COOLING SYSTEM, DRAINING AND FILLING
• COOLING SYSTEM, CHECKING FOR LEAKS
• PRESSURE RELIEF VALVE IN FILLER CAP, CHECKING
• REMOVING