Audi Workshop Service and Repair Manuals

Removing and installing thermostat

Removing –  Drain coolant → Chapter. –  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct at bottom together with air hose.

–  Loosen hose clip -2-. –  Remove bolt -4-. –  Unplug electrical connector -arrow-. –  Remove bolt -1- and take out air pipe downwards.   Note Disregard item -3-.

–  Move coolant hose -2- and electrical wiring harness -1- clear. –  Remove bolt -arrow- and remove bracket.

–  Remove bolt -2- at bracket for coolant pump for continued circulation -V51-.   Note t  The continued circulation coolant pump -V51- remains installed. t  Disregard items marked -1 and arrows-.

–  Disconnect coolant hoses -1 and 2- and move clear to one side.

Engine codes BYT, BPU –  Press release tabs, detach crankcase breather hose -arrow- and move clear to one side. –  Remove bolts -1 … 8- and detach coarse oil separator.

Engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA –  Remove bolts -1 … 9- and detach coarse oil separator. All models:   Caution Protect lubrication system against contamination. Seal off opening with clean cloth.

–  Loosen nut -2-, remove bolt -1- and swivel support for intake manifold slightly to right.

–  Unscrew bolts -arrows- and remove connection. –  Detach thermostat. Installing l  Tightening torques → Chapter „Coolant pump and thermostat - exploded view“ Installation is carried out in the reverse order; note the following:   Note Renew gaskets and O-rings. –  Clean sealing surface for O-ring. –  Coat O-ring with coolant, coolant → Electronic parts catalogue.

–  Insert thermostat -4- in coolant pump housing -5- and swivel forwards slightly -arrow-. –  Fit connection -3- carefully (insert centring pin -2- in guide -1-). –  Install coarse oil separator: engine codes BYT, BPU → Chapter; engine codes BZB, CAWB, CBFA, CCTA, CDAA, CCZA → Chapter. –  Install support for intake manifold → Rep. Gr.24. –  Install continued coolant circulation pump -V51- → Chapter. –  Install air pipes/hoses with plug-in connectors → Chapter. –  Connect coolant hose with plug-in connector → Fig.. –  Fill up with coolant → Anchor.