warning AUDI A6 1999 C5 / 2.G AEB ATW 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 using a cloth, and
open carefully to relieve system pressure
slowly.

Note:

Cooling system is under pressure when engine
is warm. If necessary reduce pressure before
repair.
Secure all hose connections using production-
type clamps parts catalog.

VAG1921 pliers are recommended for installing
spring clips.
Always replace gaskets, seals and O-rings.
Arrows on coolant lines and hoses must
align.
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19-4

Cooling system, draining and filling


Special tools and equipment

VAG1306 drip tray
VAG1274/10 with VAG1274/1 adapter or
VAG1274/8
T40007 refractometer

Draining

Note:
Drain coolant into a clean container for recycling
or reuse.

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 using a cloth, and
open carefully to relieve system pressure
slowly.

- Open coolant expansion tank cap.

- Remove noise insulation panel (arrows).
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19-10

- Start engine and maintain an engine speed of
about 2000 RPM for approx. 3 minutes.

- Allow engine to idle until the lower radiator hose
is hot.Check coolant level and top up if
necessary. When engine is at normal operating
temperature, coolant level must be at max.
mark; when engine is cold, between min. and
max. marks.

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 using a cloth, and
open carefully to relieve system pressure
slowly.

- Switch engine off.
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19-17

Note:
When installing ribbed belt, check for correct
seating on belt pulley.

- Install V-belt Page 13
-18
.

- Fill up with coolant Page 19
-6 .

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 using a cloth, and
open carefully to relieve system pressure
slowly.

CAUTION!

Be sure the ignition is switched OFF. Failure
to do so may damage the Engine Control
Module (ECM).

- Switch ignition off and reconnect battery Ground
(GND) strap.

- After connecting battery, enter anti-theft code for
radio.

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19-20

Coolant thermostat, removing, installing
and checking


Removing

- Drain coolant Page 19
-4 .

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 using a cloth, and open carefully to relieve
system pressure slowly.
Tightening torque - Remove bolts -4-, remove connector -3-, O-ring -2- and coolant
thermostat -1-.
- Clean and/or smooth O-ring sealing surface.
- Install coolant thermostat.
- Fill up with coolant Page 19
-6 .
Component
Tightening torque
Connector to pump housing 10 Nm (7 ft lb)
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19-23

Installing
Installation is the reverse of removal, noting the
following:

- Fill with coolant Page 19
-6 .

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 using a cloth, and
open carefully to relieve system pressure
slowly.
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19-24

Radiator, removing and installing


Special tools and equipment
VAG1306 drip tray

Removing

- Remove front bumper.

Repair Manual, Body Exterior, Repair Group
63


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 using a cloth, and open carefully to relieve
system pressure slowly. - Unbolt cooling pipe for power steering hydraulic oil (arrows).
- Place VAG1306 drip tray underneath engine.
- Open coolant expansion tank cap.
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19-27

Installing
Installation is the reverse of removal, noting the
following:

- Fill up with coolant Page 19
-6 .

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 using a cloth, and
open carefully to relieve system pressure
slowly.

Tightening torques

Component
Tightening torques
Condenser to radiator 10 Nm (7 ft lb)
Coolant line to radiator 10 Nm (7 ft lb)
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19-28

Cooling system, pressure test


Special tools and equipment

VAG1274 cooling system tester
VAG1274/1 adapter or VAG1274/8 with
VAG1274/9

Test condition:
Engine at operating temperature

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 using a cloth, and
open carefully to relieve system pressure
slowly.

- Open coolant expansion tank cap.

Vehicles with small cap

- Using VAG1274/1 adapter, attach VAG1274 cooling system tester to
coolant expansion tank.
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