engine AUDI A6 1995 C5 / 2.G AHA ATQ Engines Cooling System Components Workshop Manual

19-1


Cooling system components,
removing and installing

WARNING!

The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.

Notes:

Hoses are secured with spring-type clips. If
servicing, only use the same type of spring-type
clip.

Parts catalog

VAG1921 pliers are recommended when
installing spring-type clips.
The O-rings installed at the quick-release
connections must be replaced if damaged or
leaking.
Seals and gaskets must always be replaced.
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19-5


Cooling system components (on engine)

1 -
Connection
For thermostat
2 -
O-ring Always replace
3 -
Coolant thermostat Removing and installing page 19
-23
Note installation position page 19
-23
Checking:
Heat thermostat in waterOpening begins at approx. 86 C (187 F)Min. opening: 7 mm (0.28 in.)
4 -
Bleeder screw 20 Nm (15 ft lb)
5 -
Bolt 25 Nm (18 ft lb)
6 -
Retaining clip Make sure clip is seated securely
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19-6


7 -
Engine Coolant Temperature (ECT) sensor
-G62-
For Engine Control Module (ECM)If necessary, release pressure in cooling
system before removing Checking Repair Manual, 2.8 Liter V6
5V Fuel Injection & Ignition, Repair Group
01
8 -
Rear coolant line
Coolant hose connection diagram page 19
-9
9 -
Lifting eye
10 -
10 Nm (7 ft lb)
11 -
Coolant line
Coolant hose connection diagram page 19
-9
12 -
Front coolant hose
Coolant hose connection diagram page 19
-9
13 -
Sealing cap
Check using VAG1274 cooling system
tester with VAG1274/8 adapter Test pressure: 1.4-1.6 bar (20-23 psi)
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19-9


Coolant hose connection diagram

1 -
Lower coolant hose
From radiator to engine
2 -
Cylinder head/cylinder block
3 -
Intake manifold
4 -
Coolant line From heat exchanger to engine block
5 -
Heater core
6 -
Coolant hose To heat exchanger
7 -
Rear coolant line
8 -
Expansion tank
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19-11

Cooling system, draining and refilling


Draining

WARNING!

The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap with a cloth and
open carefully to relieve system pressure
slowly.

- Open coolant expansion tank cap.

- Remove noise insulation panel.
- Place VAG1306 drip tray underneath engine.

- With bumper removed, open coolant drain plug (arrow) on lower left of
radiator by turning it counterclockwise. If necessary, attach accessory
hose to connection.
-
With bumper installed, pull off retaining clamp for lower right radiator
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CAUTION!
Follow disposal regulations for coolant. hose (from radiator to engine) and disconnect radiator hose from
radiator.
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19-12


Filling
Notes: - Drain engine coolant at drain plug (arrow).
Only use coolant additive G12 (according to TL VW 7745 D). G12 is
red in color. Do not mix G12 with any other coolant additive!If the fluid in expansion tank is brown, G12 has been mixed with other
coolant. In this case, the coolant must flushed and replaced. "G12" and coolant additives marked in accordance with "TL VW 774
D" prevent frost and corrosion damage, scaling and also raise the
boiling point of the coolant. Therefore, the cooling system must be
filled year round with frost and corrosion protection additives. A higher boiling point improves engine reliability under heavy load
particularly in countries with tropical climates. Frost protection additives protect against frost to about -25 C (about -
35 C in arctic climates). The coolant concentration must not be reduced by adding water even
in warmer seasons and in warmer countries. The anti-freeze ratio
must be at least 40%.
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19-13

Note (continued from page Page 19
-12
):

If for climatic reasons greater frost protection is
required, the amount of G 12 can be increased,
but only up to 60% (frost protection to about -
40 C), otherwise frost protection and cooling
effectiveness will be reduced.

If the radiator, heat exchanger, cylinder head or
cylinder head gasket is replaced, completely
replace the engine coolant.

Test coolant frost protection using T10007 special tool.
Recommended mixture ratios: 1) The quantity of coolant can vary depending upon the equipment
installed in the vehicle. Frost protection
to Anti-freeze
amount G 121)
Water 1)
-25 C (-13 F)
-35 C (-31 F)
40 %
50 % 2.5 l (2.7
qt.)
3.0 l (3.2
qt.) 3.5 l (3.7
qt.)
3.0 l (3.2
qt.)
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19-14

- Replace coolant drain plug O-ring and install
coolant drain plug into engine.

Tightening torque: 20 Nm (15 ft lb).

- Install lower right coolant hose and secure with
retaining clip.

- Secure coolant drain valve to radiator.

- Screw VAG1274/9 onto expansion tank and insert VAG1274/10 into
adapter.

- Loosen clamp on coolant hose on heater core and pull back hose until
bleeder hole in coolant hose (arrow) is no longer sealed by connection.
- Top off coolant until it flows out from bleeder hole in coolant hose.
- Push coolant hose onto connection and tighten.
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19-15


- Loosen bleeder screw on lower coolant line (arrow) under expansion
tank (if necessary, unbolt expansion tank).
- Top off coolant until it flows out from bleeder screw.
- Close bleeder screw and tighten to 20 Nm (15 ft lb).

- Loosen bleeder screw on front coolant line (arrow) between power
steering pump and left-side of cylinder head.
- Top off coolant until it flows out from bleeder hole in coolant line.
- Close bleeder screw and tighten to 20 Nm (15 ft lb).
- Top up coolant to MAX mark.
- Install coolant expansion tank cap.
- Set heater controls to maximum heat position.
- Start engine and let run at idle for approx. 10 minutes.
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