Removing and installing coolant pipes (front): Audi A8 D3 (ASE, BMC, BPU, BVN, …)

🧭 Before you start

Fits: Audi A8 D3 (4E, 2002–2010)

• Opens: coolant
• Renewed: gaskets

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• Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.
• It is not possible to remove guide tube for oil dipstick from engine compartment at this stage.
• It is not possible to remove crankcase breather pipe from engine compartment at this stage.
• The oil supply lines remain attached to the engine.
• Clean and smoothen sealing surface for O-ring as required before installing.

🔧 Engine codes this applies to

📋 Procedure

1. Remove radiator .
2. Remove radiator cowl .
3. Remove bolts (arrows) and detach top section of air cleaner housing (right-side).
4. Move electrical wiring clear of air pipe (front left).
5. Remove air pipe (front left) (arrows).

6. Move electrical wiring clear of air pipe (front right).
7. Remove air pipe (front right) (arrows).
8. Unplug electrical connectors (1) and (2).
9. Move wiring clear. [Note: Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.]
10. To slacken poly V-belt, pivot belt tensioner in direction of (arrow) (use a lever with 3/8” drive).
11. Remove poly V-belt from alternator pulley.
12. Prise off cap for idler roller.
13. Unscrew bolt (1) and detach idler roller.
14. Remove bolt (2).
15. Pull the guide tube for oil dipstick out upwards. [Note: It is not possible to remove guide tube for oil dipstick from engine compartment at this stage.]
16. Remove bolts (1) and (2).
17. Detach crankcase breather pipe from hoses (arrows). [Note: It is not possible to remove crankcase breather pipe from engine compartment at this stage.]
18. Remove bolts (1) and (2).
19. Detach coolant pipe from hoses (arrows).
20. Remove bolt (1).
21. Remove banjo bolt (2). [Note: The oil supply lines remain attached to the engine.]
22. Remove bolt (1).
23. Detach idler roller together with spacer sleeves.
24. Remove bolts (2) and (3).
25. Detach coolant pipe from hoses (arrows).
26. Unscrew retaining clip (arrow) for power steering hydraulic line at sump.
27. Remove coolant pipe (arrows). [Note: Renew gaskets, seals and O-rings.Hose connections and hoses for charge air system must be free of oil and grease before assembly.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic parts catalogue.Fit all cable ties in the original positions when installing.]
28. Clean and smoothen sealing surface for O-ring as required before installing.
29. Lubricate new O-ring with coolant and slide onto coolant pipe.
30. Install poly V-belt .
31. Install radiator cowl .
32. Install radiator . [Note: Do not reuse coolant.]
33. Fill cooling system .

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