Audi Cars 1999-05

Removal & Installation

Print


CAUTION
NEVER open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.


NOTE
Apply an anti-seizing compound to the water pump housing fastener threads before reinstalling them.

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Turn the ignition switch to the OFF position.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Air duct at bottom of right-hand cross member
     
    Center and right-hand noise insulation under engine
     
    Accessory drive belt
     
    Vacuum hoses from carbon canister and throttle valve
     
    Coolant expansion tank and hoses
     
    Power steering reservoir, leaving hoses connected
     
    Upper and center timing belt covers
     
    Timing belt from camshaft sprocket, but leave in position on crankshaft sprocket
     
    Lower air duct
     
    Water pump
     

  8.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Water pump mount bolts: 11 ft. lbs. (15 Nm).
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Turn the ignition switch to the OFF position.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Air duct at bottom of right-hand cross member
     
    Center and right-hand noise insulation under engine
     
    Accessory drive belt
     
    Vacuum hoses from carbon canister and throttle valve
     
    Coolant expansion tank and hoses
     
    Power steering reservoir, leaving hoses connected
     
    Upper and center timing belt covers
     

  8.  
  9. Set crankshaft to TDC of No. 1 cylinder by turning central bolt on crankshaft sprocket in direction of rotation.
  10.  
  11. Insert a M5 x 55 stud into the belt tensioner. Screw hex nut onto stud using large washer.
  12.  
  13. Tension the piston of the tensioner only until it can be secured with a locking pin such as an Allen key or split pin.
  14.  
  15. Remove the timing belt from camshaft sprocket.
  16.  
  17. The vibration damper and bottom timing belt guard do not have to be removed.
  18.  
  19. The timing belt should be left in position on the crankshaft sprocket.
  20.  
  21. Cover timing belt with a cloth to protect it from coolant before removing coolant pump.

    Lower air duct
     
    Water pump
     

  22.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Water pump mount bolts: 11 ft. lbs. (15 Nm).
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

1.8L Engine



The coolant pump is bolted to the brackets for the alternator, power steering pump, and cooling fan. To gain access to the front of the engine, the front bumper must be removed and the hood lock carrier assembly moved forward to the service position.

  1. Turn the ignition switch to the OFF position, and then disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the lower engine slash shield.
  6.  
  7. Drain the engine coolant into a sealable container.
  8.  
  9. Remove the accessory drive belt, then the engine driven cooling fan.
  10.  
  11. Loosen the clamps for the coolant hoses at the water pump.
  12.  
  13. Remove the intake air duct between the intake manifold and the charge air (inter) cooler.
  14.  
  15. Remove the alternator mounting bolts and slide it forward.
  16.  
  17. Disconnect the wiring from the alternator once it is removed.
  18.  
  19. Unbolt the following supports and brackets for the alternator, power steering pump, and engine cooling fan:
  20.  


    Intake manifold support
     
    Support for the engine torque bracket
     
    Brace to the cylinder block (remove completely)
     

  21. Remove the brackets for the alternator, power steering pump, and engine cooling fan.
  22.  
  23. Position the brackets for the alternator, power steering pump, and engine cooling fan to the left side using a piece of wire.
  24.  
  25. Pull off the coolant hoses from the pump and thermostat housing.
  26.  
  27. Unbolt the coolant pump housing from the timing belt cover.
  28.  
  29. Remove the coolant pump mounting bolts, then the pump.
  30.  
  31. Unbolt the impeller housing from the pump housing.
  32.  
  33. Clean all gasket and O-ring sealing surfaces.
  34.  



Click image to see an enlarged view

Fig. The water pump, alternator and power steering pump all mount to the same engine bracket-1.8L engines



Click image to see an enlarged view

Fig. Exploded view of the water pump, housing and related components-1.8L engine

To install:

  1. Using a new gasket, mount the new coolant pump to the pump housing and tighten the mounting bolts to 84 inch lbs. (10 Nm).
  2.  
  3. Using a new gasket and O-ring, install the coolant pump and tighten the mounting bolts in numerical sequence to 18 ft. lbs. (25 Nm).
  4.  
  5. Tighten the coolant pump housing to the timing belt cover to 84 inch lbs. (10 Nm).
  6.  
  7. Install the coolant hoses to the pump and thermostat housing.
  8.  
  9. Install the brackets that were removed and tighten the mounting bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Connect the wires to the alternator, then install the alternator.
  12.  
  13. Install the air intake duct between the intake manifold and the charge air cooler.
  14.  
  15. Installation is in reverse order of removal noting the following:
  16.  
  17. Verify that the key is in the OFF position before connecting the battery
  18.  
  19. Connect the negative battery cable and if necessary, enter the radio security code.
  20.  
  21. Fill, bleed and top off the cooling system using the recommended fluid type and concentration. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  22.  
  23. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the 1-touch opening/closing function
  24.  
  25. Set the clock to the correct time
  26.  
  27. After repositioning the (hood) lock carrier, check the wiring for proper routing near the cooling fan
  28.  


NOTE
The coolant pump is bolted to the brackets for the alternator, power steering pump and cooling fan. To gain access to the front of the engine, the front bumper must be removed and the hood lock carrier assembly moved forward to the service position.



Click image to see an enlarged view

Fig. The water pump, alternator and power steering pump all mount to the same engine bracket-1.8L engines

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Turn the ignition switch to the OFF position.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Front bumper assembly and move the front inner fender lock carrier assembly forward to the lock carrier service position, on A4 models
     

  8.  
  9. With the front bumper removed, move the lock carrier assembly into the service position as follows:
    1. Release the 3 quick-release screws on the front of the lower engine splash shield.
    2.  
    3. Unbolt the air guide between the lock carrier and the air filter assembly.
    4.  
    5. Remove the 2 bolts that attach the lock carrier assembly to the side of the front fender and the 2 front bolts that mount the carrier to the top of the fender.
    6.  
    7. Remove the right side top outer bumper energy absorbing strut mounting bolt and install support tool 3369 into the top outer threaded holes on both the left and right sides of the bumper energy absorbing strut mounting surface.
      NOTE
      The 2 front bumper-to-bumper energy absorbing strut fasteners can be substituted for support tool 3369.

    8.  
    9. Remove the remaining bumper energy absorbing strut mounting bolts.
    10.  
    11. Remove the remaining 2 bolts that attach the lock carrier assembly to the top of the front fenders. Pull the lock carrier assembly forward until the rearmost bolt holes of the carrier align with the front-most threaded mounting points on the top of the front fender. Install the 2 carrier mounting bolts through the carrier into threaded mounting points of front fender to secure the lock carrier assembly in this position.
      NOTE
      The 2 front bumper mounting fasteners can be substituted for Support tool 3369.

    12.  
    13. Remove the remaining bumper energy absorbing strut bolts and pull the lock carrier out to the stop.
    14.  
    15. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.

      Click image to see an enlarged view

      Fig. The hood lock carrier assembly (1) secured in the service position with the mounting fastener (2) installed-A4 models

    16.  

  10.  
  11. Remove or disconnect the following:

    Accessory drive belt
     
    Cooling fan
     
    Lower engine slash shield
     

  12.  
  13. Loosen the clamps for the coolant hoses at the water pump.
  14.  
  15. Remove or disconnect the following:

    Intake air duct between the intake manifold and the charge air cooler
     
    Alternator mounting bolts and slide it forward
     
    Alternator wiring
     

  16.  
  17. Unbolt the following supports and brackets for the alternator, power steering pump and engine cooling fan:

    Intake manifold support
     
    Support for the engine torque bracket
     
    Brace to the cylinder block
     
    Alternator brackets
     
    Power steering pump brackets
     
    Cooling fan brackets. Position the brackets for the alternator, power steering pump and engine cooling fan to the left side using a piece of wire
     
    Coolant hoses from the pump
     
    Coolant hoses from the thermostat housing
     
    Coolant pump housing from the timing belt cover
     
    Coolant pump
     
    Impeller housing from the pump housing
     

  18.  
  19. Clean all gasket and O-ring sealing surfaces.
  20.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the water pump, housing and related components-1.8L Engine

  1. Install or connect the following:

    Coolant pump to the pump housing, using a new gasket. Torque the bolts to 84 inch lbs. (10 Nm).
     
    Coolant pump, using a new gasket and O-ring. Torque the bolts in sequence to 18 ft. lbs. (25 Nm).
     
    Coolant pump housing to the timing belt cover. Torque it to 84 inch lbs. (10 Nm).
     
    Coolant hoses to the pump and thermostat housing
     
    Brackets. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Alternator and wire connectors
     
    Air intake duct between the intake manifold and the charge air cooler
     

  2.  
  3. The remaining steps are the reverse of the removal procedure noting the following items:

    Fill the engine with coolant
     
    Verify that the key is in the OFF position before connecting the battery
     
    Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one touch opening/closing function
     
    After installing the lock carrier, check the wiring for proper routing near the cooling fan
     

  4.  

2.7L And 2.8L Engine



  1. Before servicing the vehicle, refer to the precautions section.
    NOTE
    The front bumper must be removed and the carrier assembly moved forward to the service position to gain access to the front of the engine.

  2.  
  3. Turn the ignition switch to the OFF position.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Front bumper assembly and move the hood lock carrier assembly forward and lock the carrier in the service position, on A4 and A6 models
     

  6.  
  7. On A6 models, to move the hood lock carrier into the service position, perform the following:
    1. Tag and remove any wiring or connector that would inhibit moving the carrier.
    2.  
    3. Remove the 3 quick-release screws on the front noise insulation panel.
    4.  
    5. Unbolt the air guide between the lock carrier and the air filter.
    6.  
    7. If installed, remove the retaining clamps for the wiring harness at the left side of the radiator frame.
    8.  
    9. Remove the right side top outer bumper energy absorbing strut mounting bolt and install support tool 3369 into the top outer threaded holes on both the left and right side frame rails.
      NOTE
      The 2 front bumper mounting fasteners can be substituted for the Support tool 3369.

    10.  
    11. Remove the remaining bumper energy absorbing strut bolts and pull the lock carrier out to the stop.
    12.  
    13. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.
    14.  

  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following

    V-belts and the timing belt covers
     
    Timing belt.
     
    Water pump and discard the gasket or O-ring
     

  12.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the water pump and related components-2.8L engine

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the water pump retaining bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Reinstall the timing belt.
  6.  
  7. Properly tension the belt with the water pump. Refer to the necessary service procedures.
  8.  
  9. Fill and bleed the cooling system.
  10.  

2.8L V6 Engine



On all A4 & 1998-00 Passat models, to gain access to the front of the engine, the front bumper must be removed and the (hood) lock carrier assembly moved forward to the service position.

  1. Turn the ignition switch to the OFF position, and then disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the lower engine slash shield.
  6.  
  7. Drain the engine coolant into a sealable container.
  8.  
  9. Remove the accessory drive belt, then if equipped, the engine driven cooling fan.
  10.  
  11. Remove the drive belt, and then remove the timing belt covers.
  12.  
  13. remove the timing belt.
  14.  
  15. Remove the water pump mounting bolts, then the pump.
  16.  



Click image to see an enlarged view

Fig. Exploded view of the water pump and related components-2.8L V6 Engine



Click image to see an enlarged view

Fig. Once the camshaft drive belt has been removed the tensioner and idler rollers and related component are removed to access the water pump



Click image to see an enlarged view

Fig. Once the belt guard and water pump fasteners are removed, the pump is taken off

To install:


NOTE
Always replace the old gasket(s) and/or O-ring(s).

  1. Installation is the reverse of the removal procedure. Tighten the water pump retaining bolts to 84 inch lbs. (10 Nm) for the 2.8L V6 Engines.
  2.  
  3. Reinstall the timing belt and properly tension the belt with the water pump. Refer to the necessary service procedures.
  4.  
  5. Refill and bleed the cooling system.
  6.  
  7. Enter the radio security code.
  8.  

3.0L Engine



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Turn the ignition switch to the OFF position.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine coolant
     
    Timing belt
     
    Camshaft gears from right cylinder head
     
    Idler pulley and retaining bracket
     
    Timing belt rear guard
     
    Eccentric pulley for timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Eccentric pulley for timing belt
     
    Timing belt rear guard. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Idler pulley and retaining bracket. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Camshaft gears from right cylinder head
     
    Timing belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

3.2L Engine



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

4.2L Engine



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Timing belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
label.common.footer.alt.autozoneLogo