Upper coolant pipe, not for US vehicles, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Upper Coolant Pipe, Not For Us Vehicles, Removing And Installing

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Special tools, testers and auxiliary items required

Socket 14 mm 3150
Torque wrench V.A.G 1331
Ratchet V.A.G 1331/1
Open end wrench socket 17 mm V.A.G 1331/2

Open end wrench socket 17 mm V.A.G 1331/8
Socket 14 mm T40055

Removing

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

Drain coolant → Cooling system, draining and filling .
Remove upper part of intake manifold → 24 - FUEL INJECTION SYSTEM .

CAUTION: Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure → Procedure that must be performed before opening the high-pressure fuel injection system - Pay close attention! . Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

Fig 2: Disconnecting Crankcase Ventilation Hoses At Cylinder Head Covers

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Disconnect crankcase ventilation hoses - arrows - at cylinder head covers.
Free up crankcase ventilation hoses.
Remove bolt - 1 - and remove connecting piece with crankcase ventilation hoses.

Fig 3: Identifying Union Nuts & High-Pressure Lines

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Remove high-pressure line, thereby removing bolts and union nuts - 1 through 6 -.

Fig 4: Removing Bolts And Pulling Coolant Pipe Rearward And Out Of Cylinder Block

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Place a rag under coolant pipe to catch escaping coolant.
Disconnect coolant hose - 3 - from coolant pipe.
Remove bolts - 1 - and - 2 - and pull coolant pipe rearward and out of the cylinder block - arrow -.

Installing

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

NOTE:

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

Clean and/or smooth O-ring sealing surface before installing.
Moisten new O-ring with G12+ and push onto coolant pipe.

Fig 5: Identifying Union Nuts & High-Pressure Lines

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Hand-tighten union nuts - 1 - , - 4 - and - 5 - of high-pressure lines, and then for lines - 2 - , - 3 - and - 6 -.
Make sure high-pressure lines are seated free of stress.

Fig 6: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/8

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To fasten high-pressure line (14 mm) at fuel rail use torque wrench V.A.G 1331 with 14 mm open end wrench socket V.A.G 1331/8.

Fig 7: Fastening High-Pressure Line At Fuel Rail Using Torque Wrench V.A.G 1331 With Open End Wrench Socket V.A.G 1331/2

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To fasten high-pressure line (17 mm) at fuel rail use torque wrench V.A.G 1331 with 17 mm open end wrench socket V.A.G 1331/2.

Fig 8: Fastening High-Pressure Line At High Pressure Pump Using Torque Wrench V.A.G 1331 With Ratchet V.A.G 1331/1 And Socket 17 Mm T40055

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To fasten high-pressure line (17 mm) at high pressure pump use torque wrench V.A.G 1331 with ratchet V.A.G 1331/1 and socket 17 mm T40055.
Install intake manifold upper-part → 24 - FUEL INJECTION SYSTEM .
Fill with coolant → Cooling system, draining and filling .

Torque specifications

Component		Nm
Coolant pipe to engine		9
High-pressure lines	High pressure pump	25
to	Fuel rail	25
Connecting pieces for crankcase ventilation hoses to cover		6