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Audi A4 Fan and Shroud Replacement
 
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Pelican Technical Article:

Audi A4 Fan and Shroud Replacement

Steve Vernon

Time:

2 hours2 hrs

Tab:

$80 to $500

Talent:

**

Tools:

T30, T25, T20 Torx, 100 socket, small flathead screwdriver

Applicable Models:

Audi A4 1.8 T (2002-08)

Parts Required:

New shroud or fan(s)

Hot Tip:

Work on a cool car

Performance Gain:

Proper engine temperature

Complementary Modification:

New hoses

The Audi A4 has two radiator fans in the shroud behind the radiator. These fans are usually a source of problems for the cooling system on the cars and should not be neglected when you start getting signs that the fans are going bad. One of the first things they will do is start making a fair amount of noise. If your fans start complaining it is a good sign that they are going to fail soon. If the fans fail and you do not replace them you can start to have overheating problems up to and including a blown head gasket, which is a lot more work and money than just replacing the fans.

You can replace each fan separately on the A4 or replace the shroud and fans as a unit. If both fans have the same amount of time on them and if one starts to fail it may not be a bad idea to replace them both as there is a fair amount of work to do to get access to them. If you are just replacing the fan it needs to come out the front of the shroud. If you are replacing the entire shroud and fans it can come out by moving the lock carrier to the service position. I recommend removing the radiator either way as it is very delicate, expensive. You can save the worry about damaging it while working.

To begin, move the lock carrier to the service position. If you are just replacing the fans you will also need to move the radiator out of the way. Please see our article on moving the lock carrier to the service position as well as removing the radiator.

Note: for photographic purposes we removed the lock carrier from the vehicle. While this is not necessary to perform the work there are only a couple of more steps involved after moving it to the service position. As long as you hang the A/C condenser safely out of the way it makes the job much easier.

Fan Replacement: If you are replacing the fans you will need to move the radiator out of the way.
Figure 1

Fan Replacement: If you are replacing the fans you will need to move the radiator out of the way. While all the fan connections are behind the shroud both fans must be replaced out the front of the shroud (red arrows). You can remove the radiator without breaking the lines in the A/C system. Please see our article on radiator removal for further assistance.

Fan Replacement: With the lock carrier in the service position you can get access to the fans (red arrows).
Figure 2

Fan Replacement: With the lock carrier in the service position you can get access to the fans (red arrows). Note: I have removed the lock carrier from the vehicle for photographic purposes. This is not necessary to perform the work but does give you a lot more room to work.

Fan Replacement: Both fans electrical controls (yellow arrows) run through a series of clips up to the resistor (red arrow).
Figure 3

Fan Replacement: Both fans electrical controls (yellow arrows) run through a series of clips up to the resistor (red arrow).

Fan Replacement -Cut the small zip ties (yellow arrow) and use a small flathead screwdriver to remove the small metal clips that hold the wiring in place for the fan you are removing (red arrows).
Figure 4

Fan Replacement -Cut the small zip ties (yellow arrow) and use a small flathead screwdriver to remove the small metal clips that hold the wiring in place for the fan you are removing (red arrows).

Fan Replacement: Use a 10mm socket and remove the two bolts holding the resistor to the shroud (red arrows).
Figure 5

Fan Replacement: Use a 10mm socket and remove the two bolts holding the resistor to the shroud (red arrows).

Fan Replacement - Slip the resistor from the mounting bracket in the shroud and remove the plastic cover (red arrow) that protects the wires ((yellow arrow).
Figure 6

Fan Replacement - Slip the resistor from the mounting bracket in the shroud and remove the plastic cover (red arrow) that protects the wires ((yellow arrow).

Fan Replacement - The wires are covered with a rubber insulation (yellow arrow).
Figure 7

Fan Replacement - The wires are covered with a rubber insulation (yellow arrow). The new wires on the fan should come with a clip on them (but not all manufacturers will do that) so be prepared to get some crimp clips. You will need to use a razor blade and cut the covering off of the old wiring and carefully remove the clip from the connection (red arrow).

Fan Replacement: With the wires separated from the resistor and the clips all undone, use a T25 Torx and remove the three bolts holding the fan to the shroud.
Figure 8

Fan Replacement: With the wires separated from the resistor and the clips all undone, use a T25 Torx and remove the three bolts holding the fan to the shroud. You can now remove the fan out the front of the shroud. Installation is the reverse of removal.

Shroud Replacement: If you are replacing the shroud and fans you do not need to remove the radiator, but you do need to move the lock carrier into the service position.
Figure 9

Shroud Replacement: If you are replacing the shroud and fans you do not need to remove the radiator, but you do need to move the lock carrier into the service position. Please see our article on moving the lock carrier for further assistance. The shroud assembly is held in place by four T30 bolts (red arrows) along with a series of T20 screws (yellow arrows).

Shroud Replacement: Begin by using a 10mm socket and removing the two bolts holding the resistor to the shroud (red arrows).
Figure 10

Shroud Replacement: Begin by using a 10mm socket and removing the two bolts holding the resistor to the shroud (red arrows).

Shroud Replacement - Slip the resistor from the mounting bracket in the shroud and remove the plastic cover (red arrow) that protects the wires ((yellow arrow).
Figure 11

Shroud Replacement - Slip the resistor from the mounting bracket in the shroud and remove the plastic cover (red arrow) that protects the wires ((yellow arrow).

Shroud Replacement - The wires are covered with a rubber insulation (yellow arrow).
Figure 12

Shroud Replacement - The wires are covered with a rubber insulation (yellow arrow). The new wires on the fan should come with a clip on them (but not all manufacturers will do that) so be prepared to get some crimp clips. You will need to use a razor blade and cut the covering off of the old wiring and carefully remove the clip from the connection (red arrow).

Shroud Replacement: Unclip all the wiring connected to the shroud (red arrow for example) including the lock sensor (yellow arrow).
Figure 13

Shroud Replacement: Unclip all the wiring connected to the shroud (red arrow for example) including the lock sensor (yellow arrow).

Shroud Replacement: Use a T20 Torx and remove all the Torx screws connecting the shroud to the lock carrier (red arrow for example).
Figure 14

Shroud Replacement: Use a T20 Torx and remove all the Torx screws connecting the shroud to the lock carrier (red arrow for example).

Shroud Replacement - Next use a T30 Torx and remove the two lower Torx bolts holding the shroud to the lock carrier (red arrows).
Figure 15

Shroud Replacement - Next use a T30 Torx and remove the two lower Torx bolts holding the shroud to the lock carrier (red arrows).

Shroud Replacement - Now use a T30 Torx and remove the two upper Torx bolts holding the shroud to the lock carrier (red arrows).
Figure 16

Shroud Replacement - Now use a T30 Torx and remove the two upper Torx bolts holding the shroud to the lock carrier (red arrows). You can slip the shroud and fans from the front of the vehicle. Installation is the reverse of removal.


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Comments and Suggestions:
Chris Comments: Where is the article on how to move the lock carrier into service position? Please add a hot link to the above description.
September 16, 2016
  Followup from the Pelican Staff: We are working on adding referring links to all articles.

All articles for this model are here:

http://www.pelicanparts.com/techarticles/Audi_A4_B6_Index.htm - Nick at Pelican Parts
 
nick Comments: In figure 16, what is the name of the sensor with the blue dot and what does it do? It looks like some type of pressure switch. A squirrel has chewed through the plug end of that wire and I need to replace it.
September 5, 2016
  Followup from the Pelican Staff: Looks like a hood latch switch. Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.


- Nick at Pelican Parts
 

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