Audi A4 TDI Engine Cooling System: Coolant Pipe Removal and Installation

Removing and installing coolant pipe (front)

Special tools and workshop equipment required

t	Hose clip pliers -V.A.G 1921-

Removing

–	Drain off coolant → Chapter.

–	Remove front bumper cover → General body repairs, exterior; Rep. Gr.63.

–	Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50.

–	Remove poly V-belt for power steering pump, alternator and viscous fan → Chapter

–	Remove toothed belt → Chapter.

Note

Vibration damper does not have to be unfastened and removed.

–	Take off camshaft sprocket (right-side).

–	Remove intake manifold (front section) → Rep. Gr.23.

–	Lift off centre section of rear toothed belt cover -2-.

–	Unscrew bolts -arrows- and detach rear left toothed belt cover -3- and rear right toothed belt cover -1-.

–	Disconnect both coolant hoses -arrows-.

–	Remove bolts -1- and -2-.

–	Pull off front coolant pipe towards the front.

Installing

Installation is carried out in the reverse order; note the following:

Note

t	Renew O-ring.

t	Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–	Before installing, clean and smoothen sealing surface for O-ring.

–	Lubricate new O-ring with “G12+” and slide onto coolant pipe.

–	Push front coolant pipe into coolant pipe (right-side) and into bore on cylinder block.

–	Install toothed belt (adjust valve timing) → Anchor.

–	Install poly V-belt for power steering pump, alternator and viscous fan. → Anchor

–	Install viscous fan → Chapter.

–	Install intake manifold (front section) → Rep. Gr.23.

–	Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50.

–	Install front bumper cover → General body repairs, exterior; Rep. Gr.63.

–	Fill cooling system → Anchor.

–	Dynamically check and adjust commencement of injection → Rep. Gr.23.

Tightening torques

Audi A4 Workshop Service and Repair Manuals