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Title : Best Audi A8 Fossil Oil Cooler Removal As Well As Reinstall
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Best Audi A8 Fossil Oil Cooler Removal As Well As Reinstall

Overview
The next physical care for is to live used on the A8 4.2 32 Valve (ABZ) motor. This engine was institute on the 1997 to 1999 U.S. jump A8's. This physical care for mightiness also live used for the 3.7 V8 engines, together with may live applicable to other 4.2 motors every bit well.

Please consult the Bently manual before using this procedure.

Determining if You Need this Procedure
The crude cooler has a plastic pipage amongst o-rings that carries coolant into the crude cooler, every bit good every bit a special "figure 8" crude seal to deportment crude inwards & out of the cooler. The plastic pipe, o-rings, together with crude seal degrade over fourth dimension together with start to leak. Symptoms of a leak are an unexplainable coolant leak (normally resulting inwards a depression coolant alert on the dash) or a small-scale crude leak unremarkably noticed when taking the plastic belly pan off during an crude change. It leaks a small-scale amount of oil, but it tin appear to seem similar a lot. Influenza A virus subtype H5N1 small-scale amount of crude looks similar a large occupation when leaking.

This leak tin live institute of the front end quarter of the engine on the rider side.

Approximate parts cost: $90.00, including crude filter kit & oil.
Approximate fourth dimension needed: seven hours or less.
Approximate coin saved doing it yourself: $1,000.00 US. (Including crude change.)



Oil Cooler together with Filter Exploded View. Engine block shown upside downwards amongst crude filter pointing up. Item 23 is the plastic coolant pipage that volition live replaced along amongst 22, 24 together with 25. The 3rd o-ring that is replaced is circled inwards red, the Bently manual does non release it.

*Information Required*

1. Your Radio safety code. You tin obtain this from a dealer, or you lot tin borrow/purchase the radio removal tools. If you lot produce non stimulate got your radio safety code, you lot volition demand to obtain it for your radio to function again.
2. A printed re-create of Ti Kan's Audi Radio Page, includes Delta, Concert together with Symphony programming guides.

Tools Required
(Also required are the tools listed on the Coolant Expansion Tank Replacement page.)

1. Standard 3/8" displace curt socket set, 3/8" to 13/16".
2. Metric 3/8" displace curt socket set, 8mm to 17mm.
3. Metric 3/8" displace Allen set, 4mm to 10mm.
4. 3/8" displace universal displace adapter. (Crucial)
5. 3/8" displace breaker bar.
6. 3/8" displace ratchet.
7. 3/8" displace (or 1/2" drive, amongst adaptor), 0 - fifty ft/lbs torque wrench.
8. 3/8" displace 3" extension.
9. 3/8" displace 9" extension.
10. Small 2" past times 3" mirror. (Crucial)
11. 10mm opened upwardly destination wrench.
12. Torx bit, #25, approx 1 inch long. (Crucial)
13. Number ii Phillips screwdriver
14. Number ii Flat-tip screwdriver
15. Floor Jack together with jackstands, or elevator .
16. Bottle Jack. (Extremely helpful)
17. Approx 12" long of 1" ID Conduit pipe.
    (same pipage used every bit a cheater for tranny service.)
18. 3/8" ID hose, approx 1.5 - ii feet long
19. Extremely build clean five gallon bucket.
20. Gallon milk jug, rinsed out, amongst the bottom cutting off. (funnel)
21. Oil drain pan, large plenty to concur 8 quarts.
22. Access to a VAG-COM, or VAG 1551 tool. You tin travail Steve Hall's VAG Locator
    
23. 8 - pack Guinness, for after.

Optional Tools

Parts Required

1. Oil Filter kit
2. 8 quarts oil.
3. 3 each O rings, purpose #077-121-437.
4. 1 each crude seal/gasket, purpose #077-117-411-A.
5. 1 plastic coolant pipe, purpose #077-115-441.
6. 1 gallon G12 coolant. You tin also purchase this at a VW dealer.
7. 1 tin brake cleaner.
8. 1 gyre newspaper towels.

Procedure:

Drain coolant.

1. The outset purpose required is to drain the coolant out of the engine. For this,
   follow steps 1 - 5 outlined inwards Coolant Expansion Tank Replacement.
   
   
2. Additionally, take the expansion tank fill upwardly cap.
   
   
3. After you lot stimulate got done this, drain the coolant out of the crude cooler via the 10mm bolt. If you lot utilization a peice of duct record to human activity every bit a 'chute', you lot tin drain it into the same bucket, without it collecting contaminants.
   
   Oil Cooler Coolant Drain
   

Remove air filter box.

1. After removing the top of the filter box together with associated intake hoses, you lot volition consider ii mounting studs asset the filter box. Remove the nuts. These are the exclusively fasteners asset it.
   
   Filter Box Mounting Studs
   
   
   
2. Using the flat-tip screw driver, press underneath each clip of the plastic air intake concur downwards embrace to release it.


Air Intake Hold Down



3. Next, wiggle out both plastic pipes from the residuum of the concur down, together with take the filter box.


Filter Box removed

Remove alternator/generator.
(This is why you lot demand the radio code)

1. Open the trunk. On the rider side, inwards the lilliputian compartment, take the lilliputian divider past times pulling gently but firmly up.
   
   
2. Pop upwardly the flooring of the compartment. It's velcroed on.
   
   
3. Use the 10mm wrench to disconnect the dry reason clamp. This is the clamp closest to the nurture bumper.
   
   
4. Pull downwards on the serpentine belt, making sure as shooting it is pulled below the tab, together with utilization the Torx #25 to overstep along the tension off past times placing inwards this hole:
   
   Serpentine belt tensioner concur top dog view
   
   
   Serpentine belt tensioner concur exceptional view
   
   
   
   
   Install a allen wrench or torx 25 fleck to concur tensioner to take belt.
   
   
5. Very carfully, slide the belt off the polish pulley (not grooved) that is lowest together with closest to the driver's side. (See cerise box above.) This volition live the easiest pulley. Take attention NOT to take the whole belt.
   
   
6. Delicately slide the belt off the alternator. You tin overstep along it out of the way, yet retain the belt routing past times resting it on the bracket that is used for attaching the large under-engine plastic cover.
   
   Where to residuum the belt
   
   
   
7. Using the ratchet together with 10mm socket, disconnect the top dog alternator lead.
   
   
8. Using the ratchet together with 5/16" socket, disconnect the secondary alternator lead.
   
   
9. Using the breaker bar together with a 5/8" (yes, non metric) curt socket, interruption loose the ii upper bolts that concur the alternator.
   
   DO NOT BREAK LOOSE THE LOWER BOLT AT THIS TIME.
   
   Alternator mounting points
   
   
   
10. Continue to utilization the breaker bar to loosen the ii upper bolts. It is real tight clearance, but after real few turns, you lot volition live able to unscrew them past times hand. Unscrew them completely, together with and then plough one dorsum inwards a total turn.
    
    
11. Using the ratchet together with 13mm socket, interruption loose together with take the lower bolt.
    
    
12. Supporting the alternator amongst i hand, take the terminal upper bolt.
    
    
13. If the alternator doesn't drop, swing it dorsum together with forth gently until it comes free.
    
    

Remove crude filter.

1. Position the crude drain pan nether the crude filter.
   
   
2. Using the 10mm Allen drive, 3" extension together with ratchet, interruption loose the large plug on the bottom of the crude filter. Once loose, take the tools together with unscrew past times hand. Allow filter to drain completely.
   
   
3. Using the 10mm Socket, 3" extension together with ratchet, interruption loose the retaining bolt inwards the bottom of the crude filter. Once loose, unscrew past times hand.
   
   
4. Gently wiggle off the bottom of the crude filter housing, together with the take the filter itself. Allow to destination draining. Do non exit whatever parts or crude filter inwards drain pan.
   
   
5. After draining, displace crude drain pan.
   
   

Remove Oil Cooler.
(The meat of the problem)

1. Using the breaker bar together with ratchet, 3" extension, together with 8mm Allen drive, take these ii engine mountain bolts:
   
   Engine mountain bolts to remove
   
   
   
2. Using the bottle jack together with the conduit pipe, elevator the engine past times placing the pipage on top of the Bottle Jack, together with the other destination hence it supports the large washer of the engine torque support, making sure as shooting non to elevator the whole car. The most the engine should teach upwardly is 3 inches. This allows only plenty clearance to take the 3 top bolts of the crude cooler.
   
   Placement of the bottle jack & pipe
   
   
   
3. Peel dorsum the kick on the crude pressure level switch, together with push clitoris the clip off. You may or may non stimulate got the wire tied downwards amongst a zip-strip.
   
   
4. Using the 8mm Allen drive, 3" extension, universal displace adaptor, 9" extension together with the breaker bar, you lot volition take the bolt #1. The best agency I institute was to pose thee 8mm on the 3" extension, together with and then attach the universal displace to it. You volition attach the 9" extension together with breaker bar later.
   
   Next, spell laying nether the car, overstep this upwardly through where the air filter box goes, over the large underground frame, together with into your other hand. You tin together with then manipulate it into bolt #1. It should remain in that location on it's own. Then you lot tin stand upwardly up, gently attach the 9" extension together with breaker bar into the destination of the universal drive. After you lot interruption the bolt loose, you lot tin easily switch to the ratchet.
   
   Oil Cooler Bolt Locations (front view)
   
   
   Oil Cooler Bolt Locations (side view)
   
   
   
5. After bolt #1 is removed, you lot tin straightaway take bolts ii & 3, together with and then nether the machine for bolts four & 5. As you lot take bolts four & 5, you lot may stimulate got additional coolant leak out.
   
   
6. Lower the bottle jack inwards guild to lower the engine. This volition give you lot only plenty room to teach crude cooler out.
   
   
7. Gently wiggle the crude cooler gratuitous from the engine block. Keep inwards hear that in that location is only about other coolant pipage attached, every bit good every bit guide pins inwards bolt holes 1 & 5.
   
   
8. When it's gratuitous from the block, gently wiggle the crude cooler towards the front end of the car, together with at the same time, push clitoris the front end away from the engine block. This is done inwards guild to gratuitous it from the nurture coolant pipe.
   
   Rear coolant pipage hole
   
   
   
9. Once it is gratuitous of the bolt hole pivot guides together with the nurture coolant pipe, contiinue to take from the compartment. The alternator/generator bracket expanse of the crude cooler volition in all probability live the outset to come upwardly free.
   
   (Be Sure To Remember The Orientation When It Comes Out! You'll Be Putting It Back In!)
   
   Generator Bracket Side View
   
   
   
10. After the Oil Cooler is removed, you lot volition demand to take what's left of the plastic pipage from the engine block.
    
    Broken Stub
    
    (Photo courtesy of Doug Banning)
    
    
11. To take the broken stub, uncovering a bolt amongst threads that volition lightly "screw into" the existing pipage even hence mounted on the crude cooler.
    
    Oil Cooler Back Side
    
    (Photo courtesy of Doug Banning)
    
    
12. Use the bolt to screw lightly into the broken stub even hence inwards the engine block, together with wiggle it out.
    
    
13. At this point, house the crude drain pan nether the engine crude pan, together with using the 10mm Allen drive, removed the drain plug together with drain the residuum of the oil.
    
    
14. Remove the onetime crude cooler seals together with pipe. Make certian to take the seal from the nurture coolant pipe.
    
    
15. Spray only about brake cleaner on a folded wad of newspaper towels, together with utilization it to build clean the crude cooler together with the nurture coolant pipe.
    
    
16. While you lot are at it, inspect the Air Filter box, together with build clean if necessary.
    
    
17. After cleaning, install novel seals & pipe.
    
    
18. By now, the crude should live done draining. Wipe off the drain hole, install a novel trounce washer (from the crude filter kit) onto the drain plug, together with install the drain plug. Torque to 26ft lbs. (35 Nm).
    
    
19. Wiggle the crude cooler dorsum into its space, reversing the agency you lot removed it. Make sure as shooting to wiggle it onto the nurture coolant pipe.
    
    
20. Use the mirror together with lite origin to double-check alignment.
    
    
21. Once everything is aligned, insert bolts four & five together with loosely finger tighten.
    
    Oil Cooler Bolt Locations (front view)
    
    
    
22. Once again, elevator the engine using the bottle jack.
    
    
23. Install bolts ii & 3 past times placing the bolt onto the 8mm Allen amongst 3" extension, together with using this to insert together with screw inwards finger tight.
    
    
24. Using a newspaper towel, house it betwixt the 8mm Allen displace together with bolt caput #1. Force the allen caput through the paaper towel into the allen caput opening inwards bolt #1. This volition overstep along the bolt on the allen drive.
    
    
25. Repeat mensuration E- four to insert together with finger tight bolt #1.
    
    
26. Continue to tighten the bolts inwards a circular pattern, a lilliputian at a time, until you lot tin consider both mounting surfaces meet. You may demand to repeat mensuration E-4 1 - ii to a greater extent than times to insure proper surface contact.
    
    
27. Torque bolt #1 to Torque to xviii ft lbs. (25 Nm). Follow the pattern, torqueing bolts ii & 3, together with and then four & 5.
    
    
28. Lower the engine via bottle jack, but produce non take bottle jack yet.
    
    
29. Install the ii engine mountain bolts, torqueing them to 37 ft lbs. (50 Nm). If needed utilization the bottle jack to real slightly heighten the engine for alignment.
    
    
30. Install novel crude filter. Torque retaining bolt to xviii ft lbs. (25 Nm)
    
    
31. Install a novel trounce washer (from the crude filter kit) onto the drain plug, together with install the drain plug. Torque to 37 ft lbs. (50 Nm).
    
    
32. Reinstall alternator/generator. Torque upper bolts to 33 ft lbs. (45 Nm), together with the lower bolt to fifteen ft lbs. (20 Nm). Torque large electrical connectedness nut to 12 ft lbs. (16 Nm), together with the smaller to 3 ft lbs. (4 Nm
    
    
33. Install serpentine belt, reversing the physical care for inwards mensuration C-4 together with five .
    
    
34. Install air filter box together with air intake pipes.
    
    
35. Using the gallon milk jug every bit a funnel to refill the expansion tank (slowly) amongst the saved coolant. Pay attending to the bleeder screws, together with tighten them downwards when they start to leak.
    
    
36. After pouring nigh a gallon in, banking company tally nether crude cooler for leaks.
    
    
37. Continue coolant refill, periodically checking for leaks nether crude cooler.
    
    
38. Replace expansion tank cap.
    
    
39. Refill engine amongst the 8 quarts of oil, if engine code is ABZ or AEW, together with 7.5 quarts if it's AKB, AYZ or AUX.
    
    
40. Start car, together with banking company tally for leaks.
    
    
41. If no leaks, install lower plastic pan nether engine.
    
    
42. Reconnect battery.
    
    
43. Drive machine upwardly to operating temperature.
    
    
44. Top off coolant every bit needed,
    
    
45. Recode radio. (If needed).
    
    
46. Set front end windows dorsum to express-up every bit detailed inwards owner's manual.
    
    
    
47. Crack a Guinness or three. (I had 4! -or more...)

Thus the article Best Audi A8 Fossil Oil Cooler Removal As Well As Reinstall

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