Right auxiliary cooler, 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: Drip Tray For VAS 6100, VAS 6208

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray for workshop crane VAS 6208

Removing

Drain the coolant → Cooling system, draining and filling .
Bring the lock carrier into service position → Lock carrier, moving into service position .

CAUTION: Note rules of cleanliness for working on the fuel injection system → Rules for cleanliness .

CAUTION: Fuel system is under pressure! Before opening system, place rags around connection area. Then release pressure by carefully loosening connection.

Fig 2: Installing/Removing Fuel Hose To/From Connection On Fuel Rail Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at hex head - 1 - and - 3 - and remove union nut - 2 -.

Fig 3: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air Guide Hose & Mass Air Flow (MAF) Sensor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor G70.
Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.

Move wiring harness clear at air filter housing.
Remove clip and remove air filter housing with Mass Air Flow (MAF) sensor.

Fig 4: Removing Bolts & Right Auxiliary Cooler Together With Coolant Hoses

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect upper hose on auxiliary cooler - arrow -.
Remove bolts - 1 - and - 2 -.

Fig 5: Removing Wiring Harness Bracket At Right Engine Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove wiring harness bracket at right engine plate - arrows -.

Fig 6: Disconnecting Lower Coolant Hose On Auxiliary Cooler & Removing Nuts And Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect lower coolant hose on auxiliary cooler - arrow -.
Remove nuts - 2 - and remove bracket - 1 -.
Remove right auxiliary cooler.

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 7: Installing/Removing Fuel Hose To/From Connection On Fuel Rail Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure fuel hose to connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 8: 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 .

NOTE:

Complete coolant must be replaced if the radiator was replaced.

Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

Torque specifications

Component		Nm
Bracket for auxiliary cooler to bracket for Secondary Air Injection (AIR) pump		10
Auxiliary cooler	Bracket	10
to	Long member	10 * See note
Fuel supply line to fuel rail		22

* Insert using locking compound; locking compound .