Audi Workshop Service and Repair Manuals

Removing and installing coolant pipe Special tools and workshop equipment required

t  Locking pin -T10060 A- Removing   Note Collect drained coolant in a clean container for re-use or disposal.   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27.

–  Remove the moulded insert for tools from beneath the luggage compartment floor cover. –  Unscrew the lid -arrow- of the battery compartment. –  Remove moulded insert from top of battery.

–  With ignition switched off, disconnect earth wire -arrow- at battery. –  Remove thermostat housing → Chapter. –  Pull out oil dipstick.   Note

Mark rotation direction of poly V-belt with chalk or a felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Turn tensioner in direction of -arrow- to slacken poly V-belt and lock in position with locking pin -T10060 A-.

–  Detach vacuum hose -2- from air intake hose (if fitted). –  Detach air hose -1- at the throttle valve module -J338-. –  Unplug electrical connector for air mass meter -G70- -item 3-. –  Unscrew air cleaner housing (upper section) -arrow-. –  Take out filter element.

–  Pull cover -1- off air duct (release clips on sides). –  Unclip air duct -2-.

–  Unscrew air cleaner housing (lower section) -arrows-.

–  Disconnect secondary air hose at the position marked with an -arrow-. –  Move air hose to secondary air pump clear.

–  Remove centre noise insulation -fasteners 1 ... 3-.

–  Move coolant hose at bottom of radiator cowl clear. –  Detach electrical connector -3- at secondary air pump motor -V101- and move wire clear. –  Unscrew bracket -2- for coolant pipe going to gearbox oil cooler on vehicles with direct shift gearbox. –  Remove bolts -1-. –  Loosen bolt -4- and remove secondary air pump with bracket.

–  Unplug electrical connector -1- for magnetic clutch at AC compressor and move electrical wiring clear.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew bolts -arrow- for air conditioner compressor. –  Tie up air conditioner compressor together with refrigerant hoses at front of longitudinal member (refrigerant hoses remain connected).

–  Unhook connector -arrow- for engine speed sender -G28- from bracket on guide tube for oil dipstick.

–  Unscrew bolt -3- and pull out guide tube for oil dipstick -2-. –  Unscrew bolt -4- and detach vacuum reservoir -1- from manifold. –  Move vacuum reservoir to side (hoses remain attached).

–  Unplug electrical connector -3- at continued circulation coolant pump -V51--Item 2-. –  Pull the pump downwards out of the rubber retainers on bracket. If necessary, spray rubber retainers with silicone-free lubricant. –  Unscrew bracket for continued circulation coolant pump -V51-. –  Unclip bracket for wiring harness (right-side) from coolant pipe. –  Disconnect wiring harness (left-side) from bracket at coolant pipe. –  Disconnect coolant hose to oil cooler at coolant pipe. –  Pull coolant pipe out of cylinder block. Installing Installation is carried out in the reverse order; note the following:   Note Renew O-rings. –  Before installing, clean and smoothen sealing surface for O-ring in cylinder block.

–  Lubricate new O-ring -1- with “G 12+” and push onto coolant pipe -2-. –  Push coolant pipe into bore on cylinder block. –  Install thermostat housing → Chapter. –  Install air conditioner compressor → Rep. Gr.87. –  Install poly V-belt → Chapter. –  Fill cooling system → Anchor. Tightening torque

Component	Nm
Bracket for coolant pump to bracket for ancillary units	10