Audi Workshop Service and Repair Manuals

Removing and installing thermostat Special tools and workshop equipment required

t  Drip tray for workshop hoist -VAS 6208-

t  Hose clip pliers -V.A.G 1921-

t  Locking pin -T40098- Removing   WARNING Observe notes on procedure for disconnecting battery → Electrical system; Repair group 27.

–  With ignition switched off, disconnect battery earth cable -arrow-.

–  Pull off engine cover panel -arrows-.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Open filler cap on coolant expansion tank

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-release fasteners -1- and -2- and take off front noise insulation. –  Drain off coolant → Chapter.

–  Unplug electrical connector -1- from oil pressure sender. –  Also disconnect bottom coolant hose at coolant pipe -2-, and drain off remaining coolant.   Note Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Mark direction of rotation of poly V-belt.

–  To slacken poly V-belt, turn belt tensioner/damper in direction of -arrow-. –  Lock tensioner in position with locking pin -T40098-. –  Remove poly V-belt. –  Remove alternator → Rep. Gr.27. –  Remove coolant pipes (at side) → Chapter.

–  Unbolt coolant pipe -arrow- from intake manifold and place on one side.

–  Pull out retaining clip and disconnect coolant hose -1-. –  Remove bolts -2 and 3- and detach thermostat. Installing l  Tightening torques → Chapter Installation is carried out in the reverse order; note the following:   Note Renew O-ring. –  Clean and smoothen sealing surface for O-ring. –  Coat new O ring with coolant G12+. –  Install coolant pipes (at side) → Chapter. –  Fill up with coolant → Chapter. –  Install alternator → Electrical system; Repair group 27. –  Install poly V-belt → Chapter. –  Connect battery. Procedures required → Electrical system; Repair group 27.