Just completed the job using the tips from Dave New's excellent write up. Some things I found:

The inlet hose was leaking at the pump casing and also where it joins the front to rear coolant pipe near the bleed plug. The spring clamps must lose tension over time. The pump housing o-ring had also flattened & was leaking. All clamps were replaced with German Norma worm drive clamps which also made installation much easier.

<img src="http://pictureposter.audiworld.com/92513/afterrun_pump1.jpg">

<img src="http://pictureposter.audiworld.com/92513/afterrun_pump10.jpg">

Everything went smoothly apart from removing the pump outlet hose. Removing the clamp for this ***** took as long as everything else combined. On my car (2000), the rigid turbo oil feed line runs right over the spring clamp (not elsewhere as shown in Dave's pics). This meant wrestling the clamp under the pipe with less than 1cm clearance whilst accessing it from above. Needs care to ensure you don't break the oil line or the mess of vacuum hoses. Not fun.

<img src="http://pictureposter.audiworld.com/92513/afterrun_pump11.jpg">

It's a pretty tight fit wriggling it out the back. Like Dave said - be gentle &amp; patient.

<img src="http://pictureposter.audiworld.com/92513/afterrun_pump4.jpg">

Also removed the right side EGT sender to avoid straining its cable &amp; give more working room.

Dave's suggestion of dishwashing liquid on the mounting grommets worked like a charm. They popped straight in, pump installed within 15 mins.

Old pump:
<img src="http://pictureposter.audiworld.com/92513/afterrun_pump5.jpg">
<img src="http://pictureposter.audiworld.com/92513/afterrun_pump6.jpg">

Old vs new:
<img src="http://pictureposter.audiworld.com/92513/afterrun_pump7.jpg">

New outlet hose clamp:
<img src="http://pictureposter.audiworld.com/92513/afterrun_pump9.jpg">

Probably a 2 hour job overall, just took my time to avoid breaking other stuff.

 

done that a few times good that u replaced the hoses too !

 

<center><img src="http://img204.imageshack.us/img204/5504/p4151003sj8.jpg"></center><p>my just broke into hundred piece

 

I did mine the hard way, but I have a TIP. Broke an EGT and vacuum harness.

 

Thank you for this write up and pictures! I was not looking forward, however prepared, to pulling the intake mani to get this pump out. I discovered the pump was not in the gromets after the last time a mech swapped out this pump :/ no doubt due to the lack of space and a tip from AWers! I will try the soap and hope it pops in. Indeed the pump came out from the back ('00 2.7t - 6 speed).

 

I thought there was a TSB to switch to this pump...
https://www.ecstuning.com/Audi-B5_S4...ling/ES284163/
...and remote location so it is not under the manifold and subject to so much heat.