Jack27t

I am getting ready to replace my aux coolant pump in my 2002 A6 and I was wondering if there was a newer tech article that shows how to do the job with out removing the intake manifold. I have seen the electric coolant pump removal article and I was wondering if there were any others?
Finally, does anyone have any words of wisdom on this process?

Thanks in advance.

rocketman4321

I removed the intake manifold. Don't see how you could reach in there without doing that. Not hard, but a lot of disconnecting--worth labelling all the hoses. Careful taking the crimp-type hose clamps off the plastic fittings--I broke one. But it's pretty straightforward.

Jack27t

After looking aver the tech article that show replacing the aux coolant pump without removing the intake manifold I went for it. I is a little easier and a little harder than I thought. I did the job in about 2 hours. I ran into two problem areas, removing the rear spring clamp and forcing the new hoses on the pipes.

My solution to the problems:

1. use a long pair of needle nose pliers, 8 to 10 inch long, to remove the spring clamps.
2. remove the rear turbo temp sensor boxes after removing the y-pipe and air filter corrugated pipe. i needed the room. The problem I had is that there is a steel fuel line that goes over the spring clamp. I had to loosen the clamp, move it to the end of the pipe and use my other hand and a screw driver to pull and push the rubber hose off the pipe. I could not push the spring clamp on to the hose toward the pump, but off of the hose pipe union.
3. Putting the hose back on was difficult. I could slide my hand under the IM from the rear and force the hose on the pipe, but I could not do the same to the rear pipe. I used my long needle nose pliers to grab the hose and slide it on to the pipe.

The rest was easy.

mlfca

There is a TSB on this that moves the pump down next to the alternator. This is mainly due to the heat cooking the plastic pump which eventually fails.