Coolant Warning/leak - Aux Pump

[Gigi]

So for the past month my coolant leve/temp orange warning has come on and bipped. The first time I added some G12 about 2 weeks ago and it came on again yesterday. The expansion tank looks fine though I might chnage it anyway since it's only 27 bucks. I have a leak due to the auxiliary water pump nuder the intake, where the platic housing is riveted.
I am goign to have the shop change it and use my Continental Warranty. However the question for you enthusiasts is..
is there an afternarket auxiliary pump that is stronger/more reliable? Might as well get a better one if I have to replace my old one... The one ECSTuning sells look like an OEM pump.

Thanks

[TheBlueMartin]

I think they've updated the OEM design, including the two rubber supports....but dont quote me on that.

[Gigi]

Cool, I was desperate, could not find an upgraded after market part.
I am thinking about gettnig it from ECS Tuning, they are 109$ there. Then again warranty is paying I think so....

[TheBlueMartin]

Just call a dealer and ask for a part number. You can always tell if a part has been updated if there is a letter on the end of the number.

For example, 4B0 325 5435 C

The 'C' means its the third time there has been an improvement to the part (A= first change, B= 2nd, ect..). Some of the old 1.8T coil packs that were under recall would go as high as 'H' or 'K' for the new part they were re-designed so much

[Daft]

Audi made a kit to erplace the whole pump and relocate it to the front of the motor near the alternator.

I'll get you the part number for the kit tomorrow when I get to work. I did this kit on my car about 2 months ago. It's a lengthy job but well worth the effort.

[Gigi]

cool, thanks

[Gigi]

here's the faulty part...
YOU can see the leak where two platics parts meet, screwed together. Some leak at the bottom of the plastic casing. It is merely cliped to the metal section.
Also added a pic of the box for part info

[Daft]

So wait....you put the same pump type back in? I hate to say this but, it's going to fail again at some point. They never revised the pump that fits under the intake manifold. I'm still not sure why Audi keeps selling them.

The reason why Audi made the relocation kit was so that you could use a diferent pump and also place it in a much easier location to service should it ever leak again.

I really have to complete the write-up I was working on. I've just been really swamped with work and trips out of state lately.

[Gigi]

yeah ahd the car at the shop and got tired of addingh fluid... The warranty paid for it and they ahd the part handy so I told them to go ahead and do it.
I still want the upgraded part though if you have the info.

[Daft]

Here's the kit part no:

kit# 078 998 998

I was able to get the kit for $150.

It inlcudes the new pump, mounting bracket, hardware, new harness, 90 degree plastic elbow to install in old pump location and new hoses to link new pump to plumbing at lower front section of the motor.

BTW, I also have the NewSouth Powergasket. They advertised a max cooling effect of 30F at the intake manifold. I logged the car on a 90+F day and saw pretty high temps right before I replaced the pump/gasket. Unfortunately, it's never gotten that hot here since then.....

[Kievskiy]

Hey Brett, so where can i get that kit? i want to do it, and like you said oem will fail, so i wanna do it once and for all:)
Thanx.

[Kievskiy]

i am in the same boat, cant find the relocation kit anywhere :(

[Daft]

Here's a copy of the Audi TSB:

Relocation Kit TSB

All the info you'll need is in there. Part number is on the last page.

It is a dealer only kit.

[Kievskiy]

Thanx Brett, gpt you PM :)
One thing is i am so lazy to take the bumper and radiator support off...lol

[Daft]

You can actually do it without removing the radiator and radiator support.

When I did it, I just removed the bumper, passenger headlight and the trim around the A/C condenser. This gave me a little more room to get my ratchet and pliers into the area by the alternator.

You have to pull a coolant hose off so, you might as well drain the whole cooling system.

The one thing that most people aren't aware of is that there is a coolant drain plug on the bottom of the motor right near the mating edge of the motor and the transmission's bell housing. There is a recess shaped like an oval and there are 2 bolts that require hex key bits. Usually the drain plug has a few rust marks on it since coolant touches it when you drain the system. Wish I had a picture to show you...

Anyhow, once you pull that bolt out, 2 gallons of coolant pour out. Replace it when it stops and now you'll have alot less pouring down on you when you remove that small coolant pipe at the front of the motor.

The one item that I need to mention is that your car is a 2000 and the TSB only mentions 2002+ cars. I think that you might need to modify the extension harness that comes in the kit in order to make it connect properly. Other than the harness, there is nothing else that should stop you from doing the job.

[Kievskiy]

Yeah, thats the thing i saw too, as of now i am trying to search if the harness is the same or if it was changed for the newer cars kinda like they did with turbos, oh and thanx for the tip on the bumper

The one item that I need to mention is that your car is a 2000 and the TSB only mentions 2002+ cars. I think that you might need to modify the extension harness that comes in the kit in order to make it connect properly. Other than the harness, there is nothing else that should stop you from doing the job.

[MomofAudiowner]

Help. New to this and have problem with auxiliary water pump. Son had leak in 2003 A6 2.7 Turbo with 110K miles. Mechanic fixed and installed new water pump, serpentine and timing belts. He drove to grad school in NC with no problems. Next day later leaking again. Got worse, putting coolant in every day. Mechanic in home town 700 miles away said had warranty program and would refer to local mechanic. Week later, car starts smoking Car towed and told now needs new auxiliary water pump. Can the first work done be related to the new need? Help as just spent lots of $$$ to avoid big repairs during grad school and new auxiliary pump cost is $900!!!!1

[MomofAudiowner]

Can putting in a water pump, serpentine belt and timing belt cause a failure in auxiliary water pump? Mechanic installed above when fixing coolant leak and now told need auxiliary water pump.

[Daft]

Problem #1. The Aux coolant pump was probably the issue from day 1.

Problem #2. The mechanic probably didn't know that there was a aux coolant pump under the intake manifold.


Since this is a 2003, I highly advise changing the original pump out with the revised aux pump that bolts to the front of the motor instead of under the intake manifold.

As for the labor, replacing the aux pump typically requires removing the intake manifold to get proper access. Some people say that it can be done without doing so. Personally, I just can't see how one gets their hands into a 4" high opening and manuever a ratchet or hose clamp pliers. There just isn't a way to do it.

As for the replacement of the timing belt, sepentine belt and main water pump, I'm guessing that your son hadn't had it replaced at the 75K mile replacement interval and thus the mechanic believed that the main water pump was faulty. The funny part about the aux pump is that when it leaks, it is a very small leak at first and most of the leak pools in the top of the engine block and evaporates from the engine's heat. You smell a leak, see a lower coolant level in the reservior but, you find no evidence of dripping or the source of the leak. This is always a aux pump failure.

Sadly, the mechanic who did the job must have believed that there was only one place that coolant could leak from on the 2.7T.....

[Kievskiy]

Couldn't say better ! ^^ :)

[Gigi]

yup :)

my shop did the aux pump in 3 1./2 hrs I think. Pump was 120$

[jeffp477]

got my relocation kit.. thanks to brett.. bought mine through genuine audi vw parts.. for a good price too.... im working on mine today.. i'll provide pics later...

[Gumby]

You have to pull a coolant hose off so, you might as well drain the whole cooling system.

The one thing that most people aren't aware of is that there is a coolant drain plug on the bottom of the motor right near the mating edge of the motor and the transmission's bell housing. There is a recess shaped like an oval and there are 2 bolts that require hex key bits. Usually the drain plug has a few rust marks on it since coolant touches it when you drain the system. Wish I had a picture to show you...

is this the one your talking about Brett? was under my car today and i spotted it, so i snaped a picture for you. sorry it sucks i didn't have the car on ramps or anything just raised to level four so not much room to move around.

[jeffp477]

where is that pic? is thet your trans, it kinda look like the flywheel?

[xpl0sive]

do 4.2's have the AUX pump? i smell coolant in the front of my car sometimes, but never really lose any coolant from the tank... or is it my oil cooler leaking?

[Gumby]

where is that pic? is thet your trans, it kinda look like the flywheel?

it's right at the back of the engine on the bottom side near the bellhousing. it's a little on the drivers side. the big black thing is the subframe.

[julex]

if the pic is taken from below the car (the opening in bell housing would indicate so) it is not aux pump. Aux pump is on top of engine, just under intake manifold and is quite hard to spot in the maze of piping there. Your best shot is to look thru intake manifold openings.

[Gumby]

if the pic is taken from below the car (the opening in bell housing would indicate so) it is not aux pump. Aux pump is on top of engine, just under intake manifold and is quite hard to spot in the maze of piping there. Your best shot is to look thru intake manifold openings.

i know exactly where the auxilary coolant pump is. if you read my quote from Dafts post, i was asking him if that was where the coolant drain plug was. he didn't have a picture of what he was talking about.

[TheBlueMartin]

do 4.2's have the AUX pump? i smell coolant in the front of my car sometimes, but never really lose any coolant from the tank... or is it my oil cooler leaking?

No, they dont. It could be your oil cooler, your water pump shaft, or your temp sensor (or pipe it sits in). Have it checked out ASAP if you havent already.

[Daft]

i know exactly where the auxilary coolant pump is. if you read my quote from Dafts post, i was asking him if that was where the coolant drain plug was. he didn't have a picture of what he was talking about.

Sorry Matt, I missed that. Yes, that oval shaped recess you showed is the location of the coolant drain plug. It is the greenish bolt closer to the rounded end of the recess.

It requires a long reach 5mm socketed hex bit. Open the coolant reservoir and then remove the bolt. Wake sure to have something that can hold up to 2 gallons of fluid and a wide top.