Audi Workshop Service and Repair Manuals

Removing and installing auxiliary radiator (right-side) Special tools and workshop equipment required t  Drip tray for workshop hoist -VAS 6208-

Removing –  Drain off coolant → Chapter. –  Move lock carrier to service position → Chapter.   Caution Rules for cleanliness when working on the injection system → Chapter.   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection.

Rest-of-world vehicles: –  Disconnect fuel supply pipe -1- and, if fitted, the fuel return pipe -2-.

USA vehicles: –  Unscrew fuel hose from connection at fuel rail pipe. To do so, counterhold on hexagon flats -1- and -3- with open-end spanner and loosen union nut -2-.

All models: –  Unplug electrical connector -2- at activated charcoal filter system solenoid valve 1 -N80-. –  Unplug electrical connector -3- at air mass meter -G70-. –  Disconnect hose -1- leading to secondary air pump. –  Detach air intake hose -4- at air mass meter. –  Move wiring harness at air cleaner housing clear. –  Detach clip and remove air cleaner housing together with air mass meter.

–  Detach hose (top) at auxiliary radiator -arrow-. –  Remove bolts -1- and -2-.

–  Unbolt bracket for wiring harness at engine console (right-side) -arrows-.

–  Detach coolant hose (bottom) at auxiliary radiator -arrow-. –  Unscrew nuts -2- and remove bracket -1-. –  Remove auxiliary radiator (right-side). Installing Installation is carried out in the reverse order; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

USA vehicles: –  Secure fuel hose at connection for fuel rail pipe. To do so, counterhold at hexagon flats -1- and -3- with open-end spanners and tighten union nut -2-: tightening torque 22 Nm.

All models: –  Install lock carrier with attachments. –  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten bolts -arrows-. –  Install bumper cover (front). –  Fill cooling system → Anchor.   Note The coolant in the entire system must be changed if the radiator is renewed –  Check headlight adjustment → Booklet803 or → Booklet805. Tightening torques

Component		Nm
Bracket for auxiliary radiator to bracket for secondary air pump		10
Auxiliary radiator	Bracket	10
to:	Longitudinal member	10 → Note
Fuel supply line to fuel rail		22

1)  Install using locking fluid; locking fluid → Parts catalogue.