Table of contents: 3.2 TDI engines ↓ 4.2L FSI models ↓
3.2 TDI engines
1. The installation details of the coolant pump and thermostat are shown in the illustrations.
4.1a. Coolant pump and thermostat installation details (3.2 TDI engines 1st generation):
1 - Bolt, 23 Nm;
2, 7 - Bolt, 10 Nm;
3 - Right lower radiator hose;
4 - Thermostat housing;
5 - Gasket, subject to replacement;
6 - Coolant pump;
8 - Coolant pump pulley.
4.1b. Coolant pump and thermostat installation details (3.2 TDI SCR engines):
1 - Thermostat housing;
2 - Coolant hose from the radiator (lower right);
3, 9, 11 - Bolt, 9 Nm;
4 - Coolant hose to coolant pipe (upper left);
5 - Coolant hose from the "V400" EGR radiator pump;
6 - Thermostat housing for EGR;
7 - O-ring, must be replaced;
8 - Gasket, subject to replacement;
10 - Coolant pump;
12 - Coolant pump pulley;
13 - Bolt, 23 Nm.
4.1c. Coolant pump installation details (3.2 TDI engines 2nd generation):
1 - Bolt, 9 Nm;
2 - Coolant pump pulley;
3 - Bolt, 23 Nm;
4 - Coolant pump, if the seal is damaged, replace the pump.
2. Drain the coolant (see Section 2).
3. Remove the drive belt and coolant pump pulley (see sections 6, 17 or 27 Chapters 2).
4. Remove the bolts (see illustrations) and remove the coolant pump.
4.4a. Coolant pump fastener, except for 2nd generation engines.
4.4b. Coolant pump mounting, 2nd generation engines.
5. Installation is carried out in reverse order. Pre-clean the mating surfaces.
4.2L FSI models
6. The installation details of the coolant pump and thermostat are shown in the illustrations.
4.6a. Coolant pump and thermostat installation details for 4.2 TDI engines (BTR and CCFA):
1, 16 - Bolt, 9 Nm;
2, 9 - Bolt;
3 - Front lower coolant pipe;
4, 7, 10 - Sealing rings, subject to replacement;
5 - Coolant hose;
6 - Coolant pump housing;
8 - Left coolant pipe;
11 - Coolant pump drive shaft;
12 - Coolant pump;
13 - Gaskets, subject to replacement;
14 - Thermostat, supplied only in housing 15;
15 - Thermostat housing, supplied only with thermostat 14.
4.6b. Installation details of the coolant pump and thermostat for 4.2 TDI (CCFC) engines:
1 - Thermostat housing, only assembled with thermostat;
2, 15, 18 - Gaskets, subject to replacement;
3, 13, 19 - Bolt, 9 Nm;
4, 11 - Bolt;
5 - Front lower coolant pipe;
6, 9, 12 - Sealing rings, subject to replacement;
7 - Coolant pump housing;
8 - Coolant hose;
10 - Left coolant pipe;
14 - Coolant pump drive shaft;
16 - Vacuum hose;
17 - Coolant pump.
7. Remove the central front coolant pipe (see Section 7).
8. Prepare to collect the coolant and remove the coolant hose (1 in the illustration) from the thermostat housing.
4.8. Connection (1) and fastening (arrows) of the thermostat housing.
9. On CCFC engines, disconnect the vacuum hose (1 in the illustration).
4.9. Connections and fastening of the coolant pump.
On all engines, remove the bolts (arrows) and pull the coolant pump housing forward, paying attention to its drive shaft and the left coolant pipe.
10. Pull the coolant pump drive shaft out of the guide sleeve on the oil pump (see illustration).
4.10. Coolant pump drive shaft.
11. Remove the bolts (3 and 4 in the illustration) and remove the coolant pump (1) from its housing (2).
4.11. Removing the coolant pump from its housing.
12. Installation is carried out in reverse order. After the coolant pump has been pushed into the supports in the upper section of the engine oil pan, turn the crankshaft clockwise using the pulley bolt, installing the drive flange of the coolant pump on the flats of its drive shaft.
[The text is based on materials from the website: audimanual.ru]