Converting to radiator with bypass

WARNING: This page is about a different car, the 2006 Audi A8, 2005 Audi A8, and 2004 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

Work procedure

Radiator removed.

Fig 1: Identifying Hole Drawn On Fan Shroud

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On installed fan shroud, draw a hole according to dimensions - a and b - as shown in the illustration.

Dimension - a - = 136 mm.
Dimension - b - = 23 mm

Make a bore dia. 32 mm.

NOTE:

The bore must be pre-bored and then drilled to dia. 32 mm using the stepped quick-helix drill.

Fig 2: Disconnecting Hose From Coolant Pipe

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Disconnect upper right coolant hose from coolant pipe - arrow -.

Fig 3: Disconnecting Coolant Hose From Ventilation Lines

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Disconnect coolant hose - 1 - from ventilation lines.

NOTE:

Ignore - 2 -.

Vehicles with auxiliary heater:

Remove right headlight → 94 - LIGHTS, SWITCHES - EXTERIOR .

Fig 4: Disconnecting Coolant Hose From Parking Heater

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Disconnect coolant hose - C - from parking heater.

NOTE:

Ignore - A, B, D -.

Installing

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

NOTE:

Secure all hose connections using hose clamps appropriate for the model type .

Fig 5: Installing Hose Bracket On Ventilation Pipe

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Install hose bracket - arrows - on ventilation pipe as shown in illustration.
Clip hose group bypass hose into hose bracket as shown.

NOTE:

Hose group for vehicles with parking heater is shown in illustration.

Vehicles with auxiliary heater:

Fig 6: Disconnecting Coolant Hose From Parking Heater

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Connect coolant hose - C - to parking heater.
Install right headlamp → 94 - LIGHTS, SWITCHES - EXTERIOR .