Audi Workshop Service and Repair Manuals

Removing and installing coolant pipe Special tools and workshop equipment required

t  Drip tray for workshop hoist -VAS 6208-

t  Hose clip pliers -V.A.G 1921- Removing   WARNING Hot steam/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open filler cap on coolant expansion tank

–  Lift off engine cover panel -arrows-.

–  Remove noise insulation (centre) - fasteners -1 ... 3-. –  Place drip tray for workshop hoist -VAS 6208- beneath engine.

–  Turn drain screw -arrow- on radiator anti-clockwise. If necessary fit drain hose on connection.

–  Unplug electrical connector -1- from oil pressure sender. –  Also disconnect bottom coolant hose at coolant pipe -2-, and drain off remaining coolant.

–  Disconnect air intake hose -arrow- at bottom of resonator (loosen hose clip using hose clip pliers -V.A.G 1921-).

–  Detach hose -1- from air cleaner housing. –  Unplug electrical connector -2- from air cleaner housing. –  Remove bolt -3-. –  Disconnect air intake hose -4- from throttle valve unit (loosen hose clip using hose clip pliers -V.A.G 1921-). –  Take out air cleaner housing. –  Remove intake manifold → Motronic direct injection and ignition system (4-cylinder); Rep. Gr. 24; Servicing injection system.

–  Detach electrical connector -1- from retainer and move wire clear. –  Detach electrical wiring from bracket. –  Unscrew bolts -2 ... 4- and remove support for intake manifold.

–  Detach coolant hose -arrow- from coolant pipe.

–  Detach coolant hose -1- from coolant pipe. –  Remove bolts -2 ... 3- and detach coolant pipe. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets and seals. t  Lubricate O-rings with coolant. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Install intake manifold → Rep. gr.24. –  Fill up with coolant → Chapter. Tightening torques

Component			Nm
Coolant pipe to cylinder block			10
Coolant pipe to thermostat housing			10