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 -VAS 6362-

Removing –  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

–  Remove cover -1- over battery; to do so, press release tab -arrow-.

Caution Observe notes on procedure for disconnecting the battery → Rep. gr.27. –  With ignition switched off, disconnect battery earth cable -arrow-.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank.

–  Remove front right wheel. –  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove air intake hose (left-side) by lifting retaining clips -arrows- slightly.

–  Remove bolt -arrow- for air intake pipe (left-side).

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Lift retaining clip -arrow- and disconnect coolant hose from radiator.

–  Pull cover off air duct (release clips on sides) -arrows-.

–  Release clips on left and right -arrow A- and unclip air duct at bottom -2-. –  Swivel air duct (bottom) slightly to the rear and detach air duct (bottom) from retainers -3-. –  Detach air pipe -1- from air duct (bottom) -arrow B-.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Disconnect coolant hose at bottom of engine oil cooler -arrow- and drain off coolant.

–  Remove battery → Rep. gr.27. –  Remove battery tray -arrows-.

–  Remove coolant hose between engine and radiator -arrows-.

–  Detach crankcase breather hose -2-. –  Move vent hose -4- and vacuum hoses -1- clear at air intake hose. –  Remove bolt -3-. –  Swing air hose to rear and detach from turbocharger.

Vehicles with manual gearbox: –  Detach securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin -arrow-. Metal gate relay lever: –  Detach securing clip -4- for gate selector cable from gate relay lever -2- and pull cable off pin -arrow-.

Plastic gate relay lever: l  To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing. –  Pull locking device forwards onto stop -arrow 1- and lock by turning anti-clockwise -arrow 2-. –  Press gate relay lever towards front -arrow 3-.

Vehicles with manual gearbox (continued): –  Remove selector cable support bracket -arrows- from gearbox and place to one side.

All vehicles (continued): –  Remove bolts -arrows-. –  Detach air pipe (left-side) from turbocharger by lifting retaining clips -arrows- slightly. –  Remove air pipe from engine compartment downwards.

–  Set aside wiring harness in vicinity of coolant pipe. –  Remove bolts -2- and -3-. –  Detach coolant hoses -1- and -4-.

–  Detach coolant hose -arrow- at coolant hose/pipe connection.

–  Detach oil supply hose -1- from turbocharger.   Note Disregard items marked -2- and -3-.

–  Remove bolt -1- for coolant pipe. –  Disconnect coolant hose -3-. –  Detach oil supply pipe at bracket -2-.

–  Unplug electrical connector at oil pressure switch -F1-. –  Unscrew oil pressure switch -1-. –  Detach oil supply pipe going to turbocharger at retaining clip -3- and at oil filter bracket -2-. –  Detach oil supply pipe. –  Detach coolant pipe. 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 contact surface for seal.

–  Lubricate new seal -1- with coolant additive and push onto coolant pipe -2-. –  Push coolant pipe into bore on cylinder block. Vehicles with manual gearbox –  Attach and adjust selector mechanism at gearbox → Rep. gr.34. All vehicles (continued): –  Install air pipes/hoses with plug-in connectors → Chapter. –  Install battery → Rep. gr.27. –  Connect coolant hose to radiator → Fig.. –  Fill cooling system → Anchor. Tightening torques

Component			Nm
Coolant pipe to cylinder block		M7	15
		M10	40
Oil supply pipe to oil filter flange			22
Retaining clip for oil supply pipe to:	Coolant pipe		10
	Bracket		10
Bracket for wiring harness			15
Air duct (left-side) to bracket			8
Air cleaner housing to bracket			10