Audi Workshop Service and Repair Manuals

Removing and installing thermostat housing and coolant pipe (rear)

Removing –  Drain coolant → Chapter. –  Disconnect coolant hoses -arrows- from coolant expansion tank and move coolant hose (top) clear.

–  Unplug electrical connector -1- at coolant shortage indicator switch -F66-. –  Remove nut -arrow- and detach coolant expansion tank.

–  Move B+ wire -1- clear at bracket. –  Move engine wiring harness -2- clear at cable support bracket -arrow- and move to side.

Caution Risk of damage to cable end-pieces. Do not detach cable end-pieces from selector shaft lever or gear selector relay lever. The cable end-pieces must always be renewed if they have been detached. Release cable end-pieces for gear selector cable and gate selector cable as follows: –  Press locking mechanism on selector cable to front as far as stop -arrow A-. –  Turn locking sleeve as far as stop -arrow B- and lock in position. –  Pull gear selector cable and gate selector cable out of cable end-pieces. –  Detach cover cap -3- from securing clip. –  Pull out securing clip -2- and detach relay lever.   Note Disregard -items 1 and 4-. –  Detach drive shaft (right-side) from flange shaft of gearbox.

–  Remove bolts -arrows- and detach intake manifold support.

–  Unplug electrical connector -2-.   Note Disregard items marked -1- and -arrows-.

–  Detach coolant hoses -arrows-.

–  Unplug electrical connector -1- at coolant temperature sender -G62-.   Note Disregard item -2-. –  Move electrical wiring on coolant pipe (rear) clear.

–  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Remove bolts -arrows- and carefully detach thermostat housing with coolant pipe (rear) from cylinder block and remove.

–  Detach retaining clip -2- and detach coolant pipe (rear) -3- from housing -1- for thermostat -arrow-. Installing l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and O-rings. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.

–  Fit new O-ring -4- and insert coolant pipe in thermostat housing. l  Lug -3- must engage in U-shaped recess -2-. –  Secure coolant pipe with retaining clip -1-. –  Clean and smoothen sealing surface for O-ring in cylinder head. –  Lubricate O ring with coolant additive. –  Install intake manifold support → Rep. gr.24. –  Install drive shaft (right-side) → Rep. gr.40. –  Install and adjust gear selector cable and gate selector cable → Rep. gr.34. –  Fill up with coolant → Anchor.