1996 AUDI A4 AEB ATW Engines Cooling System Components Workshop Manual

19-15

Note:
Power steering pump remains installed.

- Pull off coolant hoses from coolant pump and
coolant thermostat housing.

- Unbolt coolant pump housing from toothed belt cover (arrow).
- Remove coolant pump.

- Unbolt impeller housing -1- from pump housing -4-.
Pa
ge 17 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1

19-16

Installing
Installation is the reverse of removal, noting the
following:

- Clean sealing surfaces of both housings.

- Replace gasket and O-ring.

- Insert T-head bolt into coolant pump bore.

- Mount bracket for generator, power steering pump and viscous fan with
coolant pump on cylinder block and tighten bolts in numerical
sequence.
1 - M8 x 70 bolt
2 - M8 x 110 bolt
3 - M8 x 50 bolt
4 - M8 x 90 bolt
5 - M8 x 70 bolt
6 - M8 x 100 bolt
- Install viscous fan Page 13
-14
, Fig. 1
.
- Install ribbed belt Page 13
-17
.
Pa
ge 18 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1

19-17

Note:
When installing ribbed belt, check for correct
seating on belt pulley.

- Install V-belt Page 13
-18
.

- Fill up with coolant Page 19
-6 .

WARNING!

The cooling system is pressurized when the
engine is warm. When opening the expansion
tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and
open carefully to relieve system pressure
slowly.

CAUTION!

Be sure the ignition is switched OFF. Failure
to do so may damage the Engine Control
Module (ECM).

- Switch ignition off and reconnect battery Ground
(GND) strap.

- After connecting battery, enter anti-theft code for
radio.

Pa
ge 19 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1

Radio Operating Manual
- Fully close power windows to stop.

- Operate all power window switches again for at
least one second in "close" direction to activate
"one-touch" opening/closing function.

- Set clock to correct time.
Pa
ge 20 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1

19-18

Tightening torques

Component
Tightening
torques
Impeller to pump housing 10 Nm (7 ft
lb)
Pump housing to toothed belt
cover 10 Nm (7 ft
lb)
Bracket for generator, power
steering pump and viscous fan to
cylinder block 25 Nm (18 ft
lb)
Left brace for cylinder
block/bracket for generator, power
steering pump and viscous fan
to cylinder block 25 Nm (18 ft
lb)
to bracket M10 40 Nm (30 ft
lb)
Brace for torque support/bracket
for generator, power steering
pump and viscous fan
to torque support 25 Nm (18 ft
lb)
to bracket 20 Nm (15 ft
lb)
Intake duct support
Pa
ge 21 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1

to intake duct 20 Nm (15 ft
lb)
to bracket 20 Nm (15 ft
lb)
Pa
ge 22 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1

19-19

Component
Tightening
torques
Generator to bracket for
generator, power steering pump
and viscous fan
M8 25 Nm (18 ft
lb)
M10 40 Nm (30 ft
lb)
Belt pulley to coolant pump 25 Nm (18 ft
lb)
Viscous fan to bearing 45 Nm (33 ft
lb)
Pa
ge 23 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1

19-20

Coolant thermostat, removing, installing
and checking


Removing

- Drain coolant Page 19
-4 .

Installing
WARNING!
The cooling system is pressurized when the engine is warm. When
opening the expansion tank, wear gloves and other appropriate
protection, cover the cap using a cloth, and open carefully to relieve
system pressure slowly.
Tightening torque - Remove bolts -4-, remove connector -3-, O-ring -2- and coolant
thermostat -1-.
- Clean and/or smooth O-ring sealing surface.
- Install coolant thermostat.
- Fill up with coolant Page 19
-6 .
Component
Tightening torque
Connector to pump housing 10 Nm (7 ft lb)
Pa
ge 24 of 34 Coolin
g system com
ponents, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.19.1