Audi Workshop Service and Repair Manuals

Removing and installing coolant pipe (rear) Special tools and workshop equipment required

t  Hose clip pliers -VAS 6340-

Removing   Note t  Fit all heat shields and heat insulation sleeves in the original positions when installing. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Drain off coolant → Chapter. –  Unscrew securing bolts -1- and -5- (bottom) at combination valve for secondary air system (left-side).   Note t  Shown in illustration from rear with engine removed. t  Disregard items marked -2 ... 4-.

–  Bend heat shield slightly to the side. –  Unplug electrical connector at engine speed sender -G28--arrow-.

–  Disconnect coolant hose -arrow- from rear coolant pipe (hose leads to heat exchanger for heater).

–  Unbolt heat shield -1- for drive shaft (right-side). –  Unbolt drive shaft from flange shaft on gearbox.

–  Unscrew securing bolts -4- and -5- (bottom) at combination valve for secondary air system (right-side).   Note t  Shown in illustration from rear with engine removed. t  Disregard items marked -1 ... 3-.

–  Unplug electrical connector -1- at coolant temperature sender -G62--item 2-. –  Remove intake manifold → Rep. Gr.24. –  Take out combination valve for secondary air system (left-side) and lay it aside with vacuum line connected.

–  Pull off rubber seal and detach plenum chamber cover -1- towards the front -arrows-.

–  Lever off caps -3- on windscreen wiper arms with a screwdriver. –  Slacken nuts -4- a few turns. –  Release wiper arms -2- one by one by tilting them slightly on the wiper shafts. –  Remove nuts completely and take off wiper arms.   Note Use puller (commercially available) to remove wiper arm if necessary. –  Pull off retaining clips -1- and detach cowl panel trim -5-.

–  Remove cover for electronics box in plenum chamber -arrows-.

–  Using a screwdriver, carefully lever out retaining strap -arrow- and remove engine control unit from electronics box.   Note The engine control unit remains connected to the wiring harness.

–  Release retaining hooks -arrows- outwards and remove retaining strap.

–  Unplug all electrical connectors at connector point -2-. –  Unscrew electrical wiring -1-.

–  Release retainers -arrows- and push auxiliary relay carrier in electronics box upwards to remove. –  Detach the engine wiring harness at electronics box and at bulkhead.

–  Unplug electrical connectors -1- and -2-. –  Move electrical wiring harness clear. –  Place the wiring harness on top of engine and secure the engine control unit to prevent it falling.

–  Remove bolts -1- and -3-. –  Detach coolant hose -2- going to coolant hose/pipe connection. –  Move heat insulation sleeves -arrows- above coolant connecting hoses (right and left) on rear coolant pipe to the side. –  Loosen hose clips using spring type clip pliers -VAS 5024 A- and move coolant connecting hoses to the side. –  Remove electrical connectors -4- and -5- from brackets on coolant pipe (rear). –  Remove coolant pipe (rear) towards the left. Installing Installation is carried out in the reverse order; note the following:   Note t  Renew O-rings. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  Fit all heat shields and heat insulation sleeves in the original positions when installing. t  Fit all cable ties in the original positions when installing. –  Before installing, clean and smooth down sealing surfaces for O-rings as required. –  Coat new O-rings with acid-free grease (vaseline), fit coolant pipe (rear) and tighten. –  Install combination valves for secondary air system: left-side → Chapter, right-side → Chapter. –  Install intake manifold → Rep. Gr.24. –  Install and adjust wiper arms → Rep. Gr.92. –  Fill cooling system → Anchor. Tightening torques

Component	Nm
Coolant pipe (rear) to cylinder head	9
Drive shaft heat shield to gearbox	23