Rear coolant line, removing and installing

WARNING: This page is about a different car, the 2010 Audi A8, 2009 Audi A8, 2008 Audi A8, and 2007 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

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Hose clamp pliers V.A.G 1921

Removing

NOTE:

During installation, all cable ties must be re-installed at the same location.

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Pull rear engine cover - arrows - off.
Drain coolant → Cooling system, draining and filling .
Remove right secondary air injection combi-valve → Right combination valve for Secondary Air Injection, removing and installing .

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Remove rear sound insulation by loosening fasteners - 2 and 4 -.

NOTE:

Ignore items - 1 and 3 -.

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Remove bracket for noise insulation - arrows -.

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Loosen hose clamp - arrow -.

NOTE:

Ignore items - 1 to 5 -.
To improve clarity, the removed engine is shown from the rear.

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Loosen hose clip - 1 - at coolant hose.

NOTE:

Ignore - arrows -.

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Disconnect electrical connection - 1 - at throttle valve control module J338.
Remove bolts - arrows - and remove Throttle Valve Control Module J338.

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Disconnect electrical connector - 2 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and remove vacuum hose - 1 -.
Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 from bracket and lay aside with hose connected.

NOTE:

Disregard - arrow -.

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Remove electrical connectors - 1 through 4 - from bracket.
Remove nut - arrows - and remove right electrical connectors bracket from bulkhead.

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Remove coolant hose - 2 - by pulling clip out slightly.

NOTE:

Ignore - 1 -.

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Remove air guide hose - 1 -.

NOTE:

Ignore items - 2 and 3 -.
To improve clarity, the removed engine is shown from the rear.

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Remove crankcase ventilation hose - 1 and 2 -.
Remove bolts - 3 and 5 - and press crankcase ventilation pressure regulator valve from throttle valve connections.
Remove oil drain hose - arrow -.

NOTE:

Ignore - 4 - and Hose Clamps Up to 25 mm dia. 3094.
To improve clarity, the removed engine is shown from the rear.

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Remove oil dipstick - 10 - from guide tube.
Remove bolts - 2 and 5 -.
Disconnect electrical connectors - 1, 3, 4, 6, 8 - and free up wiring harness.
Remove Hall sensor - 9 -.

Place wiring harness on engine.

NOTE:

Ignore - 7 -.

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Disconnect vacuum lines - arrows - to brake booster.
Lay vacuum lines aside.

NOTE:

Ignore - 1 -.

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Remove bolt - 1 - and remove oil dipstick guide tube upward.
Remove bolts - 2 and 3 - and remove left coolant pipe from coolant hoses - arrows -.
Place coolant pipe back slightly.

NOTE:

Ignore items - 4 and 5 -.

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Remove coolant hose - 2 - to intake manifold.
Disconnect electrical connector - 3 - on Engine Coolant Temperature (ECT) Sensor G62.
Remove nuts - 5 -.
Remove bracket with electrical connectors and wiring harness from rear coolant pipe.

Remove bolts - 1 and 4 -.
Remove rear coolant pipe from right coolant pipe - arrow -.
Remove rear coolant pipe to right side of vehicle.

NOTE:

To improve clarity, the removed engine is shown from the rear.

Installing

Tightening torques → Coolant pipes, assembly overview .

Installation is in reverse order of removal, note the following:

NOTE:

Replace O-rings.
Secure all hose connections using hose clamps appropriate for the model type .
During installation, all cable ties must be re-installed at the same location.

Clean or smooth O-ring sealing surfaces.
Install right secondary air injection combi-valve → Right combination valve for Secondary Air Injection, removing and installing .
Install left coolant pipe → Left coolant pipe, removing and installing .
Install Hall sensor → Valvetrain, assembly overview .

Install Throttle Valve Control Module J338 → 24 - MULTIPORT FUEL INJECTION (MFI) .
Install crankcase ventilation pressure regulator valve → 24 - MULTIPORT FUEL INJECTION (MFI) .
Fill with coolant → Filling .