javanator

<a href="https://forums.audiworld.com/a4gen2/msgs/1108028.phtml" target="_new">Earlier post</a>

Decided to quit and leave it alone last night since I was not getting anywhere with detaching the coolant hose from the flange. No amount of grunting and cussing could get the coolant hose detached from the flange by just pulling it apart. The extruded groove on opposite sides of the flange where the hosed attached meant no twisting action could be applied.

This morning, found a length of PCV pipe in the garage. Cut a piece off about a foot long and with a hammer used it to whack on the exposed lip of the coolant hose -- removed the metal clip first. It came off after about the fifth/sixth whack. Unbelievable!

<img src="http://www.ampproject.com/audi/images/coolant-flange/pic-3.jpg">

The coolant hose was connected on the part nearest the hammer in this pic. As you can see, it was crusted up with some white stuff. You can see one of the extruded grooves.

<img src="http://www.ampproject.com/audi/images/coolant-flange/pic-4.jpg">

The inside of the flange opening with the o-ring that connects to the coolant hose was bad. The inside part is supposed to have a raised inner part to it, forming a groove that the o-ring is supposed to fit in. The lip was pretty much gone, and the remaining part(s) still connected were very brittle -- it all broke off very easily. The bottom of opening shows a piece of the lip that I salvaged.

<img src="http://www.ampproject.com/audi/images/coolant-flange/pic-5.jpg">

Here is a pic showing the new flange inner lip that makes the groove the o-ring sits in. Image is from <a href="https://www.audiworld.com/tech/eng76.shtml" target="_new">BSK's Coolant Flange Replacement write up</a>.

<img src="http://www.ampproject.com/audi/images/coolant-flange/pic-7.jpg">

What's odd is that the old o-ring is too big for the diameter of the opening it goes into. Go figure.

<img src="http://www.ampproject.com/audi/images/coolant-flange/pic-6.jpg">

Overall, it's not too hard of a job, just took some time. There's quite a few things to take off or disconnect. Taking the oil feed line off is key. Had to go buy a set of flex-racheting closed-type wrenches because the top bolt that holds the flange on does not have enough room to get a socket w/standard size rachet in there. A 10mm flex racheting wrench with <a href="http://www.sears.com/shc/s/p_10153_12605_00942801000P?keyword=9-42801&sLevel=0" target="_new">a set of these</a> worked quite well -- they turn your racheting wrench into a low-profile setup.

x1rider

nice work! "friendly" and a ball peen hammer don't really go together though!

javanator

Was given to me from my Dad, who he got from my Grandpa. It has persuaded many a situation on assorted cars and tractors in it's 60-or-so years. It's years of experience definitely helped me with the predicament I was in.

x1rider

haha, great, as long as you know when to "hold back"!!!