gk1

This is listed as a TSB for the 2.7T 2002 and up, where a different pump is placed near the alternator and the stock pump under the intake manifold is replaced with an elbow.

Let me start by saying I don't recommend doing this one. It is likely easier/better to just replace the stock pump with a new one and get another 5 years out of it.

It's not that is tremendously difficult to do, but it is a cramped working environment if you don't want to remove the intake and the bumper + radiator support. That coupled with the fact that you have to re-pin the wiring harness the kit comes with and the metal bracket has no place to bolt up to for an '01.5 is why I don't recommend doing this swap.

However I will list the part numbers and pics for anyone interested.

Repair Kit part number:
078 998 998
This includes the following parts:
078 121 601 B Auxiliary coolant pump
078 121 096 AQ Coolant hose
078 121 096 AR Coolant hose
N 906 870 01 B27x12 Spring clamps * 2
078 121 521 F Bracket for auxiliary coolant pump (This does not fit on an '01.5)
N 101 244 08 Bolt with hex socket head M6x20 (Holds pump to bracket also not needed)
N 100 835 02 Screw hex head self cutting M6x16 (Holds bracket to car also not needed)
078 121 147 Angled elbow
4B0 971 379 Wiring harness adapter (Needs to be re-pined and wires reversed contrary to logic.)

The TSB also required 2 other parts:
078 121 092 shrink tubing for the large lower radiator house...I assume for abbrasion resistance.
8D0 971 946 connector housing to adapt the harness to the car for 2002 and also worked on the '01.5.


078 998 998 Repair Kit
<img src="http://pictureposter.audiworld.com/14154/8_30_2006_aux_coolant_pump_parts_001.jpg">



078 121 601 B Auxiliary coolant pump
<img src="http://pictureposter.audiworld.com/14154/8_30_2006_aux_coolant_pump_parts_009.jpg">

<img src="http://pictureposter.audiworld.com/14154/8_30_2006_aux_coolant_pump_parts_006.jpg">

078 121 096 AQ Coolant hose
078 121 096 AR Coolant hose
N 906 870 01 B27x12 Spring clamps * 2
078 121 521 F Bracket for auxiliary coolant pump (This does not fit on an '01.5)
N 101 244 08 Bolt with hex socket head M6x20 (Holds pump to bracket also not needed)
N 100 835 02 Screw hex head self cutting M6x16 (Holds bracket to car also not needed)
078 121 147 Angled elbow
<img src="http://pictureposter.audiworld.com/14154/8_30_2006_aux_coolant_pump_parts_017.jpg">

4B0 971 379 Wiring harness adapter
<img src="http://pictureposter.audiworld.com/14154/8_30_2006_aux_coolant_pump_parts_015.jpg">

078 121 092 shrink tubing
<img src="http://pictureposter.audiworld.com/14154/8_30_2006_aux_coolant_pump_parts_014.jpg">

8D0 971 946 connector housing
<img src="http://pictureposter.audiworld.com/14154/8_30_2006_aux_coolant_pump_parts_022.jpg">

erik9108

bookmarked for later use. Thanks!

VR6guy

Screw that, I'd rather replace the thing twice than do that once.

OCA::DIY Motorsports

So would this be a warranty replacement thing? I'm still under factory warranty.

davenew

for info: I replaced the stock pump without removing the manifold.. maybe 1-2 hrs?

gk1

Since I didn't want to disturb the intake manifold. That would be the same if you just replaced the leaky stock pump. That part is something I would not like to do again. Now that I've completed that once and put in the elbow I should likely not have to go in there again.

Second hardest was re-pinning the wiring harness, but that isn't really hard at all if you are familiar with VAG style pins and connectors. They key was that the harness is wired incorrectly, or the wiring is different on 2002+ models. Logic dictates 1 goes to 1, 2 goes to 2 and red goes to red while brown goes to brown. This needed to be swapped for whatever reason. I verified the pump won't/can't run backwards if you reverse polarity...it simply doesn't run at all.

The reason I don't really recoomend it is the bracket doesn't fit on a pre 2002 model. I am willing to go without it since the pump is housed in a rather large hard rubber donut and held in palce with the two short hoses. I also added a zip-tie for extra holding. However perhaps that is just me and that is why in good conscience I can't recommend it.

gk1

Getting the front hose on was a pita. Also the spring clamps were impossible to get back on. I dumped em and used regular screw clamps.

gk1

But who knows if they will actually follow the TSB or just replace the stock pump.

BlackS4tt (Josh)

are you serious? wow........!

davenew

I doubt this method would work on tips, since they have something back behind the engine.<ul><li><a href="https://forums.audiworld.com/s4/msgs/2169710.phtml">https://forums.audiworld.com/s4/msgs/2169710.phtml</a></li></ul>