Audi Workshop Service and Repair Manuals

Removing and installing 4/2-way valve Special tools and workshop equipment required

t  Removal lever -80 - 200-

t  Hose clip pliers -VAS 6340-

t  Hose clip pliers -VAS 6362-

Removing –  Drain coolant → Chapter. –  Remove air cleaner housing → Rep. gr.23.

–  Version for countries with cold climates: Unplug electrical connector -2-. –  Press release tabs and disconnect crankcase breather hose -1-. –  Disconnect vacuum hose -arrow-. –  Remove bolt -3-, swivel air pipe with connection to rear and detach from turbocharger.   Note Disregard -item 4-.

–  Unclip wiring harness from retainer -arrow-.

–  Release hose clips -1- and -2- and remove air hose.

–  Remove bolts -arrows-. –  Using removal lever -80 - 200-, move clear electrical wiring and hoses at air pipe (left-side). –  Loosen hose clip -3- and detach air pipe (left-side).

–  Release hose clips -1-, detach coolant hoses and move clear.   Note Disregard -items 2, 3, 4-.

–  Take electrical connector -1- for Hall sender -G40- out of retainer. –  Remove bolts -arrows-, pull off coolant pipe (front) from 4/2-way valve to left side and leave in installation position.   Note Disregard -items 2, 3-.

–  Release hose clips -1- and -2- and remove air hose. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove bolts -arrows-. –  Move coolant hose -3- clear. –  Loosen hose clip -2-. –  Unplug electrical connector -1- at charge pressure sender -G31-/intake air temperature sender -G42- and detach air pipe (right-side).

–  Pull oil dipstick out slightly and remove bolt -1-. –  Release clip -2- with removal lever -80 - 200-. –  Pull guide tube for oil dipstick upwards out of cylinder block and push to one side.

–  Remove bolts -2-. –  Loosen hose clips -1, 3, 4-, detach coolant hoses and remove 4/2-way valve with thermostat. Installing l  Tightening torque → Chapter „Coolant pump and thermostat - exploded view“ Installation is carried out in the reverse order; note the following: –  Install dipstick guide tube → Chapter. –  Install coolant pipe (front) → Chapter. –  Install air pipes → Chapter. –  Install intake connecting pipe → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install battery mounting and battery → Electrical system; Rep. gr.27. –  Install air cleaner housing → Rep. gr.23. –  Install air hoses with screw-type clips → Fig.. –  Fill up with coolant → Anchor.