Rear coolant pipe, removing and installing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Spring-Type Clip Pliers VAS 6340

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hose clamp pliers VAS 6340

Removing

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Drain coolant → Cooling system, draining and filling .
Bring lock carrier into service position → Lock carrier, moving into service position .
Remove right coolant pipe → Right coolant pipe, removing and installing .
Remove engine support bridge 10-222 A from engine compartment.

NOTE:

Engine support bridge was necessary to remove right coolant pipe, but it hinders the following work sequence.

Fig 2: Removing Coolant Hoses & Coolant Expansion Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove coolant hoses - 1 - and - 2 -.
Remove coolant expansion tank - arrow -.
Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch F66 at bottom of expansion tank.

Fig 3: Removing Bracket For Electrical Harness Connectors At Left From Bulkhead

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove electrical harness connectors - 1 to 4 - from bracket at left of bulkhead.
Remove bracket from bulkhead.

Fig 4: Disconnecting Brake Booster Vacuum Hose From Grommet On Bulkhead

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum line - arrow - to brake booster at bulkhead.

Fig 5: Disconnecting Coolant Hose To Heater Core At Rear Coolant Pipe On Engine

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hose to heater core at rear coolant pipe on engine.

Fig 6: Disconnecting Coolant Hose From Y-Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hose from Y-connector - arrow -.

Fig 7: Disconnecting Electrical Harness Connector For Camshaft Position (CMP) Sensor 2 G163 On Left Cylinder Head

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 G163 on left cylinder head.

NOTE:

The following illustration shows the engine as removed, from behind.

Fig 8: Pressing Sealing Ring For Crankshaft At Rear Out Of Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor G40 on right cylinder head.

Fig 9: Disconnecting Electrical Harness Connector On Engine Coolant Temperature (ECT) Gauge Sensor G2/G62

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect the electrical connector - 2 - on Engine Coolant Temperature (ECT) Gauge Sensor G2/G62.
Remove nut - 1 - and remove electrical wiring harness at rear coolant pipe.

Fig 10: Removing Bolts & Rear Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen hose clips - 1 - using Hose Clip Pliers VAS 6340.
Loosen hose clip - 6 - using Hose Clips Pliers VAS 6340 and remove coolant hose.
Remove bolts - 2 to 5 -.
Remove rear coolant pipe.

Installing

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 and/or smooth O-rings sealing surface before installing.
Coat new O-rings with non-corrosive lubricant (Vaseline), install rear coolant pipe and tighten.
Install right coolant pipe → Right coolant pipe, removing and installing .
Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 11: Placing Torque Support On Rubber Buffer For Torque Support

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Fill with coolant Filling .
Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

Torque specifications

Component	Nm
Rear coolant pipe to cylinder head	10
Retaining clamps to rear coolant pipe	10