Coolant pump, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Pin Wrench 3212

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pin wrench 3212

Removing

Fig 2: Identifying Front Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove front engine cover - arrows -.

Fig 3: Identifying Bolts & Air Duct

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows -.
Remove air duct - 1 - and - 2 -.
Drain coolant → Cooling system, draining and filling .
Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.

Bring lock carrier into service position →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

NOTE:

Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

Fig 4: Pivoting Tensioning Device To Relieve Tension On Ribbed Belt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pivot tensioning device in direction of - arrow - to relieve tension on ribbed belt.
Remove ribbed belt from coolant pump.
Release tensioner unit

Fig 5: Locating Bolts And Spanner Wrench 3212 To Counter-Hold

Courtesy of VOLKSWAGEN UNITED STATES, INC.

When loosening bolts use Spanner Wrench 3212 to counter-hold.
Remove ribbed belt pulley from coolant pump.
Pry off cover cap.

Fig 6: Disconnecting Idler Roller

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - arrows - and disconnect idler roller.

Fig 7: Removing Bolts For Coolant Pump And Coolant Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - for coolant pump and remove coolant pump.

Installing

Installation is in reverse order of removal, note the following:

Clean sealing surfaces so they are completely free of any oil or grease.

NOTE:

If the previously used coolant pump is reinstalled, apply a 1.5 mm thick sealant bead to the cleaned sealing surface in addition to the seal that has been vulcanized on.

Install ribbed belt Installing .
Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Fill with coolant → Cooling system, draining and filling .

Torque specifications

Component	Nm
Coolant pump to cylinder block	9
Ribbed belt pulley to coolant pump	20
Idler roller to cylinder block	40