Radiator — removal and installation (Audi A6 C5)

Removal

Cars with gasoline engines

1. Remove the cap from the coolant expansion tank.

Caution! When the engine is hot, place a rag on the expansion tank cap before removing it to avoid being burned by hot coolant or steam. Remove the cap only when the coolant temperature is below +90°C.

2. Cars with parking heater. Unscrew the bolts (see arrows in the illustration) fastening the parking heater pipe to the noise-insulating shield.



3. Press the fasteners 1 and 2 and remove the front part of the engine splash guard (see illustration).





4. Remove the front bumper (see the relevant chapter).

5. Place a suitable container or tray under the engine to collect the coolant.

6. Unscrew the plug (see arrow in illustration) drain hole on the thermostat housing and drain the coolant.



7. Remove the left fairing (see arrow in illustration) additional radiator.



8. Disconnect the lower hose from the radiator by removing the mounting clamp (see arrow in illustration).





9. Cars with automatic transmission. Clean the corresponding bolts before unscrewing (see arrow in illustration) and disconnect the transmission fluid lines from the radiator.

Caution! Collect the leaking transmission fluid in a suitable container and prevent contaminants from entering the lines by placing plastic bags on the disconnected ends and clamping them with rubber bands.

10. Press the latches and remove the air filter cover 2 (see illustration).



11. Unscrew the bolts (see arrows in illustration 5.10) fastening the air intake 1 to the upper front cross member and remove the air intake.



12. Disconnect the upper hose from the radiator (see arrow in illustration).



13. Unscrew the bolts (see arrows in the illustration), press the fasteners and remove the left and right radiator fairings.



14. Disconnect the outside air temperature sensor 1 and release the wire from the holder (see illustration).





15. Unscrew the bolts (see arrows in illustration 5.14) power steering line holders and move the line away from the work area without opening the system. Carefully tie up the line to avoid damaging it.

16. Vehicles with air conditioning. Disconnect plug 1 of the refrigerant pressure sensor (see illustration).



17. Unscrew the bolts (see arrows in illustration 5.16) air conditioner radiator mounts and remove the radiator. Carefully tie the radiator to the body with wire, without disconnecting the hoses and refrigerant circulation pipes from it. Do not allow the hoses to bend or twist.

Warning! Do not open the refrigerant circulation system yourself - risk of frostbite! If refrigerant gets on your skin, rinse it immediately with cold water for at least 15 minutes. The refrigerant is colorless, odorless and heavier than air. If the refrigerant leaks, people in the area of the floor on which the vehicle is installed or in rooms located below the leak may suffocate.

Caution! Do not stretch, bend or twist air conditioning pipes and hoses.

18. Release the top of the radiator from the clips by pressing them upwards with a screwdriver (see arrows in the illustration).



19. Move the radiator forward and carefully remove it.

Diesel Engine Cars

20. Drain the coolant (see the relevant chapter).

21. Disconnect the lower hose from the radiator.

22. Remove the intercooler (see the relevant chapter).

23. Press the fasteners and remove the air filter cover 2, and also remove the air intake 1 (see illustration).





24. Unscrew the mounting bolts (see arrows in the illustration) and remove the upper engine protective cover.



25. Cars with automatic transmission. Clean the corresponding bolts before unscrewing (see arrow in illustration) and disconnect the transmission fluid lines from the radiator.



26. Disconnect the upper hose from the radiator (see arrow in illustration).





27. Release the top of the radiator from the clips by pushing them upwards with a screwdriver (see arrows in illustration 5.18).

Installation

The radiator is installed in the reverse order of removal.

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