Rear coolant line, removing and installing

WARNING: This page is about a different car, the 2008 Audi RS 4 and 2007 Audi RS 4. 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 5024 A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Spring-type clip pliers VAS 5024 A

Removing

NOTE:

During installation, re-install all heat insulation sleeves and heat shields at the same locations.
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 .

Fig 2: Removing Bolts At Bottom Of Left Secondary Air Injection Combination Valve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 - and - 5 - at bottom of left secondary air injection combination valve.

NOTE:

The illustration depicts the engine removed from behind.
Ignore items - 2 to 4 -.

Fig 3: Removing On Engine Speed (RPM) Sensor G28 At Left Of Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bend heat shield slightly to side.
Disconnect electrical connector on Engine Speed (RPM) Sensor G28 - arrow -.

Fig 4: Removing/Installing Coolant Hose To Heater Core On Rear Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove coolant hose - arrow - to heater core on rear coolant pipe.

Fig 5: Removing Heat Shield For Left Drive Axle

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove heat shield - 1 - for right drive axle.
Remove drive axle from transmission flanged shaft.

Fig 6: Removing Bolts At Bottom Of Right Secondary Air Injection Combination Valve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 4 - and - 5 - at bottom of right secondary air injection combination valve.

NOTE:

The illustration depicts the engine removed from behind.
Ignore items - 1 to 3 -.

Fig 7: Disconnecting Electrical Connector On Engine Coolant Temperature (ECT) Sensor G62

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector - 1 - on Engine Coolant Temperature (ECT) Sensor G62 - 2 -.
Remove intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .
Remove left secondary air injection combination valve and lay it aside with vacuum line connected.

Fig 8: Identifying Plenum Chamber Cover & Rubber Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rubber seal and remove plenum chamber cover - 1 - forward - arrows -.

Fig 9: Removing Securing Clips And Cowl

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry off cover caps - 3 - from wiper arms with a screwdriver.
Loosen nuts - 4 - several turns.
Loosen wiper arms - 2 - one after another by tilting wiper axles slightly.
Remove nuts completely and remove wiper arms.

NOTE:

If wiper arm cannot be removed in this way, use a standard puller.

Disconnect securing clips - 1 - and remove cowl grille - 5 -.

Fig 10: Removing Screws And Cover From E-Box In Plenum Chamber

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover for E-Box in plenum chamber - arrows -.

Fig 11: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from E-Box.

NOTE:

Engine Control Module (ECM) remains connected at wiring harness.

Fig 12: Releasing Retaining Hooks Toward Outside And Removing Retaining Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release retaining hooks - arrows - toward outside and remove retaining bracket.

Fig 13: Disconnecting All Electrical Harness Connectors On Connector Station & Electrical Wire Connection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect all electrical harness connectors on connector station - 2 -.
Remove electrical wire connection - 1 -.

Fig 14: Disengaging Locking Mechanisms And Removing Secondary Relay Carrier In E-Box Toward Top

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
Disengage engine wiring harness at E-Box and bulkhead.

Fig 15: Disconnecting Electrical Connectors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connectors - 1 - and - 2 -.
Free up wiring harness.
Set electrical wiring harness on engine and secure Engine Control Module (ECM) against falling down.

Fig 16: Identifying Bolts, Coolant Hose, Electrical Connectors & Heat Insulation Sleeves

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - 1 - and - 3 -.
Remove coolant hose - 2 - to coolant connections.
Slide heat insulation sleeves - arrows - over left and right coolant connection hoses at rear coolant pipe to side.
Loosen hose clips with Spring Type Clip Pliers VAS 5024 A and slide coolant connection hoses to side.

Remove electrical connectors - 4 - and - 5 - from bracket at rear coolant pipe.
Remove rear coolant pipe to left.

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, re-install all heat insulation sleeves and heat shields at the same locations.
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 secondary air injection combination valve: Left → Left combination valve for secondary air injection (AIR), removing and installing , right → Right combination valve for secondary air injection, removing and installing .
Install intake manifold → 24 - MULTIPORT FUEL INJECTION (MFI) .

Mount wiper arms and adjust →
- 92 WINDSHIELD WIPER WASHER SYSTEM
- 92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET
.
Fill with coolant Filling .

Torque specifications

Component	Nm
Rear coolant pipe to cylinder head	9
Heat shield for drive axle to transmission	23