How to change engine thermostat on Audi A4 B5 saloon – replacement guide
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Recommended replacement interval for the part category Thermostat : 50000km
Important!
This replacement procedure can be used for:
AUDI A4 Saloon (8D2, B5) 1.8,
AUDI A4 Saloon (8D2, B5) 1.8 T,
AUDI A4 Saloon (8D2, B5) 1.8 quattro,
AUDI A4 Saloon (8D2, B5) 1.8 T quattro,
AUDI A4 Saloon (8D2, B5) 1.8 T quattro,
AUDI A4 Saloon (8D2, B5) 1.8 T,
AUDI A4 Saloon (8D2, B5) 1.8,
AUDI A4 Saloon (8D2, B5) 1.8 quattro,
AUDI A4 Saloon (8D2, B5) 1.6
…
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The steps may slightly vary depending on the car design.
How to change engine thermostat on AUDI A4 B5 Saloon [TUTORIAL AUTODOC]
All the parts you need to replace – Thermostat for A4 Saloon (8D2, B5) and other AUDI models
Check the condition of the coolant every time you replace the thermostat. Change the coolant if necessary.
All work should be done with the engine stopped.
Carry out replacement in the following order:
Step 1
Open the hood.
Step 2
Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
Step 3
Unscrew the engine cover fastener. Use HEX No.H5. Use a ratchet wrench.
Step 4
Remove the engine cover.
AUTODOC recommends:
Replacement: engine thermostat – Audi A4 B5 saloon. Do not use excessive force when removing the part as this may damage it.
Step 5
Unscrew the coolant reservoir cap.
Step 6
Prepare a container for fluids.
Step 7
Clean the coolant hose. Use all-purpose cleaning spray.
Step 8
Disconnect the coolant pipe retaining clip.
Step 9
Detach the coolant hose.
Replacement: engine thermostat – Audi A4 B5 saloon. Professionals recommend:
Caution! Coolant may leak out of the coolant lines and thermostat housing.
Step 10
Drain the coolant from the engine.
Replacement: engine thermostat – Audi A4 B5 saloon. Tip:
Caution! The coolant can be very hot.Wear gloves to prevent contact with hot liquid.All work should be done with the engine stopped.Wait until the coolant has completely flowed out of the drain hole.
Step 11
Clean the coolant hose. Use all-purpose cleaning spray.
Step 12
Attach the coolant hose.
Step 13
Connect the coolant pipe retaining clip.
Step 14
Clean the coolant hose. Use all-purpose cleaning spray.
Step 15
Pull aside the V-ribbed belt tensioner pulley. Use a combination spanner #17.
Step 16
Remove the V-ribbed belt.
Replacement: engine thermostat – Audi A4 B5 saloon. Tip from AUTODOC:
Check the condition of the tensioner pulley and idler pulley. Replace them if necessary.
Step 17
Return the tensioner pulley to its initial position.
Step 18
Remove the battery cover.
Step 19
Unscrew the fasteners of the car battery terminals. Use a combination spanner #10.
Step 20
Remove the battery terminals.
Step 21
Loosen the alternator fasteners. Use HEX No.H8.
Step 22
Unscrew the fastener of the viscous fan clutch. Use a combination spanner #46. Use HEX No.H8.
Step 23
Loosen the alternator fasteners. Use HEX No.H8.
Step 24
Remove the alternator.
Step 25
Disconnect the alternator connector.
Step 26
Unscrew the alternator power cable fastener. Use a combination spanner #13.
Step 27
Clean the thermostat housing. Use all-purpose cleaning spray.
Step 28
Unscrew the thermostat housing fasteners. Use a drive socket #10. Use a ratchet wrench.
Step 29
Remove the thermostat housing.
AUTODOC recommends:
Replacement: engine thermostat – Audi A4 B5 saloon. Do not use excessive force when removing the part as this may damage it.
Step 30
Remove the thermostat. Use pincers.
Replacement: engine thermostat – Audi A4 B5 saloon. Tip:
Do not apply excessive force when removing the part. Otherwise you may damage it.Caution! Coolant may leak out of the coolant lines and thermostat housing.
Step 31
Clean the thermostat housing mounting seat. Use a wire brush. Use all-purpose cleaning spray.
Step 32
Install a new thermostat.
AUTODOC recommends:
Replacement: engine thermostat – Audi A4 B5 saloon. Do not use excessive force during installation. This may damage the part.
Step 33
Treat the thermostat housing. Use a sealant.
Step 34
Install the thermostat housing.
Replacement: engine thermostat – Audi A4 B5 saloon. Tip from AUTODOC:
When installing, do not use excessive force to avoid damage to the part.
Step 35
Tighten the thermostat housing fasteners. Use a drive socket #10. Use a torque wrench. Tighten it to 6 nm torque.
Step 36
Tighten the alternator power cable fastener. Use a drive socket #13. Use a torque wrench. Tighten it to 5 nm torque.
Step 37
Connect the alternator connector.
Step 38
Install the alternator.
Step 39
Tighten the alternator fasteners. Use HEX No.H8. Use a torque wrench. Tighten it to 8 nm torque.
Step 40
Tighten the fastener of the viscous fan clutch. Use a combination spanner #46. Use HEX No.H8. Use a torque wrench. Tighten it to 24 nm torque.
Step 41
Pull aside the V-ribbed belt tensioner pulley. Use a combination spanner #17.
Check the condition of the tensioner pulley and idler pulley. Replace them if necessary.
Step 43
Return the tensioner pulley to its initial position.
Step 44
Remove the coolant reservoir cap.
Step 45
Insert the funnel.
Step 46
Pour coolant in the coolant reservoir.
Replacement: engine thermostat – Audi A4 B5 saloon. AUTODOC recommends:
Only use the coolant recommended by the manufacturer.The coolant level should be at the MAX mark.Wait until the air goes out of the system.
Step 47
Attach the terminals to the battery.
Replacement: engine thermostat – Audi A4 B5 saloon. Tip from AUTODOC:
Be careful! Do not mix up the positive and the negative terminals of the car battery.
Step 48
Screw in the fasteners of the battery terminals. Use a combination spanner #10.
Step 49
Treat the battery terminals. Use dielectric grease.
Step 50
Install the battery cover.
Step 51
Run the engine for a few minutes. This should be done in order to remove residual air from the cooling system and to check if the components are operating correctly.
Step 52
Shut off the engine.
Step 53
Install the coolant reservoir cap.
Step 54
Screw on the coolant reservoir cap.
Step 55
Install the engine cover and secure it.
AUTODOC recommends:
Replacement: engine thermostat – Audi A4 B5 saloon. Do not use excessive force during installation. This may damage the part.
Step 56
Screw in the engine cover fasteners. Use HEX No.H5. Use a ratchet wrench.
Step 57
Check the coolant level. If necessary, top up to the required level.
Step 58
Remove the fender protection cover.
Step 59
Close the hood.
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