Removing and installing auxiliary water pump: Audi 2.7 (AGB, AZB)

AZB
Notes:

All hose connections are secured with clips.
Charge air system must be free of leaks.
Renew all seals and gaskets

Removing

Unscrew bolts -arrows- and remove engine cover panels -A...C-.
Remove front bumper:

=> General body repairs; Repair group 63; Front bumper; Removing and installing front bumper
General body repairs
Front bumper
Removing and installing front bumper

Move lock carrier to service position

=> General body repairs; Repair group 50; Removing and installing lock carrier; Lock carrier service position

Remove viscous fan (counter-hold with pin wrench 3212).

Note:

Viscous fan has left-hand thread: turn in direction indicated.

Remove air duct -arrows-.

Pull off brake servo hose -1- at bulkhead.
Disconnect earth wire from exhaust temperature sender (left side).
Unscrew exhaust temperature senders from intake manifold (left and right sides) => Fitting locations overview, Page
10-32
.

Remove coolant reservoir -arrows- and move it clear to the side.

Note:

Leave coolant hoses connected.

Unplug connector from coolant level monitor.

Remove cover panel from cylinder head cover (cylinder bank 4-6).
Disconnect hose -2-.

Pull off hose -1- for vacuum reservoir.
Unplug connector from air recirculation valve -2-.

Remove cover above air cleaner.

Warning
Fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
Disconnect fuel supply line and fuel return line -1- and -2-, and move fuel lines clear.
Pull hose off ACF valve -3-.
Remove cover panel from cylinder head cover (cylinder bank 1-3).

Pull connectors off injectors -2- on cylinder bank 4 - 6.

Unplug connectors from injectors -2- (cylinder bank 1..3).
Pull off hose -5- going to turbocharger intake side.

Unclip solenoid valve for charge pressure control -1-.
Pull connector off ACF valve -2-.

Pull connector off throttle unit -1-.
Pull connector off charge air sensor -2-.
Pull off crankcase breather -3-.
Pull connector off intake air temperature sensor -4-.

Remove pressure pipes -1-.

Note:

Watch position of retaining strips -2-.

Unbolt intake manifold using special tool 3249.
Pull off connector for auxiliary water pump.
Fit clamps 3094 on water hoses for auxiliary water pump.
Remove auxiliary water pump.

Installing

Install in the opposite order to removing. When installing, note the following points:

Counterhold viscous fan pulley using pin wrench 3212 and secure viscous fan using open-end spanner 3312 and torque wrench 1331 (left-hand thread).

Note:

Viscous fan has left-hand thread: turn in direction indicated.

Install lock carrier in normal position

=> General body repairs, Exterior; Repair Group 50; Body front; Lock carrier service position

Install bumper

=> General body repairs, Exterior; Repair group 63; Front bumper; Removing and installing front bumper - Assembly overview
General body repairs, Exterior
Front bumper
Removing and installing front bumper - Assembly overview

Tightening torques

Component · Nm
Bolts · M6 · 10
Bolts · M8 · 20
Intake manifold to cylinder head · 10
Torque wrench V.A.G 1331 / and open-end spanner 3312 · 37 Nm
Torque wrench / without open-end spanner 3312 · 70 Nm