Audi Workshop Service and Repair Manuals

Removing and installing coolant pipe Special tools and workshop equipment required

t  Hose clip pliers -V.A.G 1921-

Removing –  Drain off coolant → Chapter. –  Remove engine cover panel -arrows-.

–  Detach hoses -1-, -3- and -4-. –  Release spring-type hose clips -2- and -5- and remove air hose.

–  Disconnect hoses -1- and -2- from air cleaner housing. –  Remove bolt -3-. –  Take out air cleaner housing.

Vehicles with engine code BGU: –  Unplug electrical connector -1-. –  Disconnect hoses -2- and -3- at secondary air pump. –  Detach secondary air pump -4- from bracket.

–  Unscrew bolts -1- and -2- and nut -3- on secondary air pump bracket. –  Detach bracket.

All vehicles (continued): –  Unplug electrical connectors: 1 -  Engine speed sender -G28- 2 -  Knock sensor 1 -G61- 3 -  Ignition coil 1 -N- and ignition coil 2 -N128- with output stage -N122- 4 -  Oil pressure switch -F1- (on oil filter bracket) –  Move wiring clear. –  Remove ignition coil assembly.

–  Remove wiring harness bracket -2- and ignition coils bracket -1-. –  Remove crankcase breather pipe -arrows-.

–  Disconnect coolant hose -arrow- from coolant pipe (hose leads to heat exchanger for heater). –  Unscrew securing bolt -1- on coolant pipe.

–  Disconnect front coolant hoses at coolant pipe. –  Detach coolant pipe -2- from connection. –  Remove O-ring -1-. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew gaskets, seals and O-rings. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Clean and smoothen sealing surface for O-ring as required. –  Lubricate new O-ring -1- with coolant and push O-ring onto coolant pipe -2-. –  Push coolant pipe into bore on cylinder block. –  Install ignition coil assembly → Rep. gr.28. –  Fill cooling system → Anchor. Tightening torques

Component	Nm
Coolant pipe to cylinder block	40
Bracket for ignition coil to cylinder block	15
Bracket for wiring harness to cylinder block	10
Ignition coil to bracket	10
Bracket for secondary air pump to intake manifold	23
Secondary air pump to bracket	10