2.0l - Cooling System - Engine Code(s): Cbfa & Ccta Audi A3 8P рестайлинг 2

COOLING SYSTEM, DRAINING AND FILLING

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Drip Tray VAS 6208
3. Hose Clip Pliers V.A.G 1921
4. Cooling System Charge Unit VAS 6096
5. Refractometer T10007

Draining

Open coolant reservoir cap.

Remove noise insulation. Refer to Removal and Installation .

Cabriolet

Remove the noise insulation bracket. Refer to Removal and Installation .

All

Remove the air guide pipe -1 and 2-.

Scheme 1

Note. Drained coolant must be stored in a clean container for disposal or reuse.

Place VAS 6208 under engine.

Remove the lower coolant hose -1- from the radiator and let the coolant drain.

Scheme 2

Note. Ignore -2-.

Remove lower coolant hose to after-run coolant pump -V51- -arrow- and allow coolant to drain.

Scheme 3

Filling

Note. The cooling system is filled year year-round with a mixture of water and coolant additive. Mixture ratio COOLING SYSTEM, DRAINING AND FILLING . Only use coolant according to the Other coolant additives may above all reduce the corrosion protection effect significantly. The damage resulting from this may lead to loss of coolant and consequently to severe engine damage. Coolant with the correct mixture ratio COOLING SYSTEM, DRAINING AND FILLING prevents freezing and corrosion damage and calcium deposits. They also raise the boiling point. The cooling system must be filled with coolant additive year-round. Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates. Protection against frost must be assured to about -25 °C (-77 °F) (in arctic climatic countries to about -35 °C (-95 °F)). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. Coolant additive portion must be at least 40%. If more freeze protection is needed due to the climate, increase the amount of coolant additive, but only up to 60% (freeze protection down to -40 °C (-104 °F)). Otherwise the freeze protection and cooling effectiveness will be reduced. Only use clean drinking water for mixing coolant. If radiator, heat exchanger, cylinder head or head seal or cylinder block were replaced, do not reuse used coolant. Dirty coolant may not be used again. Use the T10007 to determine the level of freeze protection in the coolant system. Secure all hose connections with hose clamps appropriate for the model.

Coolant mixture ratio

1. Coolant (40%) and water (60%) for freeze protection down to -25 °C (-77 °F)

1. Coolant (50%) and water (50%) for freeze protection down to -35 °C (-95 °F)

1. Coolant (60%) and water (40%) for freeze protection down to -40 °C (-104 °F)
2. Coolant

Connect the lower coolant hose -1- to the radiator.

Connect coolant hose to after-run coolant pump -V51- -arrow-.

All

Fill the coolant reservoir on the VAS 6096 with at least 10 liters of premixed coolant with the proper mixture ratio COOLING SYSTEM, DRAINING AND FILLING .

Attach V.A.G 1274/8 to coolant reservoir.

Install VAS 6096 on V.A.G 1274/8.

Place air outlet -1- in a small container -2-.

Note. A small amount of coolant which should be collected is drawn off with the discharged air.

Close valves -A- and -B- by turning lever at a right angle to direction of flow.

Connect hose -3- to compressed air.

1. 6 to 10 bar positive pressure.

Open valve -B- by turning level in direction of flow.

Scheme 4

1. The suction jet pump generates pressure in the coolant system; indicator on display instrument must move into green area.

Briefly open valve -A- by turning lever in direction of flow so that hose on VAS 6096 coolant reservoir fills with coolant.

Close valve -A- again.

Leave valve -B- open another 2 minutes.

1. More pressure is generated in the coolant system by the suction jet pump; indicator on display instrument must stay in green area.

Close valve -B-.

1. Needle in the display instrument must remain in the green region, then the sufficient vacuum in the cooling system is obtained for the upcoming filling.

Note. If needle stands below the green area, repeat procedure. If pressure falls, check coolant system for leaks.

Remove pressurized air hose.

Open valve -A-.

1. Coolant is extracted from the VAS 6096 coolant reservoir by pressure in the coolant system and the system is filled.

Check coolant level.

Scheme 5

Fill coolant up to "max" marking.

Start engine and run at approximately 1500 RPM for a maximum of 2 minutes.

With engine running, fill coolant up to overflow hole on coolant expansion tank.

Close the cap on the coolant reservoir.

Start the engine and let it run at approximately 3000 RPM until the coolant fan starts running.

Check coolant level.

1. With warm engine, coolant level must be at "max" marking, with cold engine, between "min" and "max" marking.

If necessary, top off with coolant again.

Shut off engine.

COOLANT HOSE CONNECTION DIAGRAM

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Secure all hose connections using hose clamps appropriate for the model. Hose clip pliers V.A.G 1921 or spring-type clip pliers VAS 5024 A are recommended for installing spring-type clamps. Always replace gaskets and seals. Arrows on coolant pipes and coolant hoses must line up across from each other.

With Manual Transmission

Note. The -arrows- point in the coolant flow direction.

Scheme 6

1. Radiator
2. After-Run Coolant Pump -V51
3. Coolant Pump
4. Coolant Thermostat
5. Engine Oil Cooler
6. Cylinder Head and Cylinder Block
7. Turbocharger
8. Coolant Reservoir With sealing cap Pressure relief valve in cap, checking, refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__cooling-system-checking-for-leaks)
9. To Auxiliary Heater
10. From the Auxiliary Heater
11. Heater Core
12. Coolant Connection

Vehicles with a S-Tronic Transmission

Note. The -arrows- point in the coolant flow direction.

Scheme 7

1. Radiator
2. After-Run Coolant Pump -V51
3. Coolant Pump
4. Coolant Thermostat
5. Engine Oil Cooler
6. Cylinder Head and Cylinder Block
7. Turbocharger
8. Coolant Reservoir With sealing cap Pressure relief valve in cap, checking, refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__cooling-system-checking-for-leaks)
9. To Auxiliary Heater If applicable
10. From the Auxiliary Heater If applicable
11. Heat Exchanger for Heater Unit
12. Transmission Oil Cooler
13. Coolant Connection
14. Coolant Thermostat for the Transmission Fluid Cooler

Scheme 8

1. Bracket
2. Bolt 5 Nm
3. Coolant Hose
4. Coolant Hose
5. After-Run Coolant Pump -V51
6. Bracket
7. Bolt 8 Nm

COOLANT PIPES OVERVIEW

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Secure all hose connections using hose clamps appropriate for the model type, Hose clip pliers V.A.G 1921- or spring-type clip pliers VAS 5024 A- are recommended for installing spring-type clamps. Always replace gaskets and seals. Arrows on coolant pipes and coolant hoses must line up across from each other.

Scheme 9

1. Front Coolant Pipes Removing and installing, refer to «FRONT COOLANT PIPES»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__front-coolant-pipes)
2. Coolant Hose From turbocharger
3. Coolant Hose To the coolant reservoir
4. Bolt 5 Nm
5. O-ring Replace
6. Coolant Hose To heat exchanger for heater unit
7. Small Coolant Pipe Removing and installing, refer to «SMALL COOLANT PIPE»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__small-coolant-pipe)
8. Bolts 9 Nm
9. Coolant Hose
10. Bolt 5 Nm
11. Coolant Hose From after-run coolant pump -V51
12. Coolant Hose To the after-run coolant pump

COOLANT PUMP AND THERMOSTAT ASSEMBLY OVERVIEW

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Secure all hose connections using hose clamps appropriate for the model type, Hose clip pliers V.A.G 1921- or spring-type clip pliers VAS 5024 A- are recommended for installing spring-type clamps. Always replace gaskets and seals. Arrows on coolant pipes and coolant hoses must line up across from each other.

Scheme 10

1. Bolt Tightening order «COOLANT PUMP AND THERMOSTAT ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pump-and-thermostat-assembly-overview)
2. O-rings Replace
3. Connection
4. Retaining Clip Only with the inserted version Make sure it is secure
5. Bolt 4 Nm Only with the threaded version
6. Retaining Plate Only with the threaded version
7. Engine Coolant Temperature (ECT) Sensor -G62- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__engine-coolant-temperature-sensor)
8. O-ring Replace
9. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pump) With a new coolant pump, remove the protective cap
10. Seal Replace
11. Centering Pin Quantity: 2
12. Toothed Belt For coolant pump Removing and installing, refer to «COOLANT PUMP TOOTHED BELT»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pump-toothed-belt)
13. Toothed Belt Guard
14. Bolt 9 Nm
15. Bolt Replace 10 Nm plus an additional 90° turn Left thread
16. Toothed Belt Drive Gear Pay attention to the installed position.
17. Shaft Seal Replacing «COOLANT PUMP DRIVE SHAFT SEAL»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pump-drive-shaft-seal) .
18. Balance Shaft
19. Coolant Thermostat Removing and installing, refer to «COOLANT THERMOSTAT»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-thermostat)
20. Centering Pin
21. O-ring Replace
22. Connecting Piece
23. Bolt 9 Nm

Scheme 11

Tighten the coolant pump bolts to 9 Nm in a -1 to 5- sequence.

RADIATOR AND COOLANT FAN OVERVIEW

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Secure all hose connections using hose clamps appropriate for the model. Hose clip pliers V.A.G 1921 or spring-type clip pliers VAS 5024 A are recommended for installing spring-type clamps. Always replace gaskets and seals. If there are small impressions on the fins. Refer to COOLERS, CONDENSERS AND CHARGE AIR COOLERS, INSTALLING . Arrows on coolant pipes and coolant hoses must line up across from each other.

Scheme 12

1. Coolant Fan -V7- Removing and installing, refer to «COOLANT FAN AND COOLANT FAN 2»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-fan-v7-and-coolant-fan)
2. Nut 10 Nm
3. Fan Shroud
4. Lower Coolant Hose To the connection for the coolant thermostat
5. Clamp
6. Engine Coolant Temperature (ECT) Sensor -G62- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__engine-coolant-temperature-sensor)
7. O-ring Replace if damaged
8. Upper Coolant Hose From coolant pump
9. O-ring Replace if damaged
10. Bolt 5 Nm On the charge air cooler
11. Radiator Removing and installing, refer to «RADIATOR»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__radiator) After replacing replace entire amount of coolant Engines with a radiator identification sensor -G611-, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__radiator-and-coolant-fan-overview)
12. Nut 10 Nm
13. Bolt 5 Nm On the radiator
14. Coolant Fan 2 -V177- Removing and installing, refer to «COOLANT FAN AND COOLANT FAN 2»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-fan-v7-and-coolant-fan)

Scheme 13

Remove the old O-ring -2- in the coolant hose -3-.

Coat new O-ring with coolant and install it in the coolant hose.

Press the coolant hose onto the connection -1- until it engages audibly.

Press the coolant hose on again and pull to make sure the connection is engaged correctly.

Scheme 14

Arrow- indicates direction of travel

A- Radiator

B- Radiator Identification Sensor -G611

Note. The radiator identification sensor -G611- can be replaced only with the radiator.

FASTENER TIGHTENING SPECIFICATIONS

Coolant Pump Tightening Sequence

Tighten the coolant pump bolts to 9 Nm in a -1 to 5- sequence.

COOLING SYSTEM, CHECKING FOR LEAKS

Special tools and workshop equipment required

1. Cooling System Tester V.A.G 1274 B
2. Adapter V.A.G 1274/8
3. Adapter V.A.G 1274/9

Procedure

1. Engine at operating temperature.

Open coolant reservoir cap.

Scheme 15

Position V.A.G 1274 B with V.A.G 1274/8 on coolant reservoir.

Generate approximately 1 bar pressure using the cooling system tester hand pump.

If pressure falls, search for leaks and correct problem.

Check the Pressure Relief Valve Inside the Cap.

Scheme 16

Attach V.A.G 1274 B with V.A.G 1274/9 to sealing cap.

Generate pressure with cooling system tester hand pump.

1. The pressure release valve must open at 1.4 to 1.6 bar.

If pressure relief valve does not open as specified, replace cap.

AFTER-RUN COOLANT PUMP -V51

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094
2. Hose Clip Pliers V.A.G 1921

Removing

Open coolant reservoir cap.

Remove noise insulation. Refer to Removal and Installation .

Cabriolet

Remove the noise insulation bracket. Refer to Removal and Installation .

All

Disconnect the electrical connector -1- for the after-run coolant pump -V51-.

Scheme 17

Place drip tray VAS 6208 under engine.

Disconnect the coolant hoses -arrows- together with the 3094.

Remove coolant hoses from after-run coolant pump.

Remove the bolt -2- and the after-run coolant pump.

Installing

1. Tightening specifications, refer to «AFTER-RUN COOLANT PUMP ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta) .

Installation is in the reverse order of removal, note the following

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

FRONT COOLANT PIPES

Special tools and workshop equipment required

1. Hose Clip Pliers V.A.G 1921
2. Drip Tray VAS 6208

Removing

Open coolant reservoir cap.

Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Scheme 18

Unclip the lower air guide, to do so disengage the clips -arrows-.

Scheme 19

Remove the lower air guide together with the air guide hose.

Loosen the hose clamp -2-.

Scheme 20

Remove bolt -4-.

Disconnect the connector -arrow- and free up the wire.

Note. Ignore -1 and 3-.

Remove noise insulation. Refer to Removal and Installation .

Cabriolet

Remove the noise insulation bracket. Refer to Removal and Installation .

All

Remove the air guide pipe -1 and 2-.

Remove the bolt -1- and remove the air guide pipe downward.

Note. Ignore -2, 3, 4 and arrow-.

Place VAS 6208 under engine.

Remove the coolant hoses from the after-run coolant pump -V51- -arrows-.

Note. Ignore -1 and 2-.

Disconnect the vacuum line -1- to the EVAP canister by pressing the release button.

Scheme 21

Note. Ignore -2-.

Disengage the vacuum line on the front coolant pipes.

Remove the EVAP canister with the connected lines upward out of the bracket -arrow- and lay it aside.

Scheme 22

Remove the bolts -1 and 2- and remove the front coolant pipes from the coolant hoses -arrows-.

Scheme 23

Installing

1. Tightening specifications, refer to «COOLANT PIPES ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pipes-overview) .

Installation is in reverse order of removal, note the following

Note. Always replace gaskets and seals. Secure all hose connections with hose clamps appropriate for the model.

Air guides, installing with connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

SMALL COOLANT PIPE

Special tools and workshop equipment required

1. Hose Clip Pliers V.A.G 1921

Removing

Drain coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Unclip the lower air guide, to do so disengage the clips -arrows-.

Remove the lower air guide together with the air guide hose.

Disconnect electrical connector -1- on mass air flow (MAF) sensor -G70-.

Scheme 24

Remove the air guide hose -2-.

Remove the bolt -4- and the air filter housing.

Note. Ignore -3-.

Loosen the hose clamp -2-.

Remove bolt -4-.

Disconnect electrical connector -arrow-.

Remove the bolt -1- and remove the air guide pipe downward.

Note. Ignore -3-.

Remove the bolts -arrows- and remove the electrical connectors -1 through 3- from the bracket.

Scheme 25

Free up the wiring harness on the small coolant pipe -arrow-.

Scheme 26

Remove bolts -2 and 3-.

Disconnect the small coolant pipe from the coolant pump and from the coolant hoses -1 and 4-.

Installing

1. Tightening specifications, refer to «COOLANT PIPES ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pipes-overview) .

Installation is in reverse order of removal, note the following

Note. Secure all hose connections with hose clamps appropriate for the model.

Air guides, installing with connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

ENGINE COOLANT TEMPERATURE SENSOR

Removing

1. Engine cold.

Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Unclip the lower air guide, to do so disengage the clips -arrows-.

Remove the lower air guide together with the air guide hose.

Remove the air guide hose -2 and 3-.

Note. Ignore -1, 2 and arrows-.

Disconnect electrical connector -1- on throttle valve control module -J338-.

Scheme 27

Remove bolts -arrows- and remove throttle valve control module.

Remove the intake manifold support; to do so, remove the nut -2- and bolt -1-.

Scheme 28

Note. Different engine coolant temperature (ECT) sensor -G62- may be installed, depending on the version.

Inserted version

Disconnect the electrical connector -1- on the engine coolant temperature (ECT) sensor.

Scheme 29

Note. Lay a cloth below to catch escaping coolant.

Remove the clamp, to do so, press the latches -arrow-.

Remove the engine coolant temperature (ECT) sensor -2-.

Threaded version

Disconnect the electrical connector -2- on the engine coolant temperature (ECT) sensor.

Scheme 30

Note. Lay a cloth below to catch escaping coolant.

Remove the bolts -arrows- and the retaining plate -1-.

Remove the engine coolant temperature (ECT) sensor.

Installing

Installation is in the reverse order of removal, note the following

Note. Replace O-ring. To prevent coolant loss, immediately insert new engine coolant temperature (ECT) sensor in connecting pieces.

Install the intake manifold support. Refer to Description and Operation .

Install throttle valve control module. Refer to Description and Operation

Check coolant level COOLING SYSTEM, DRAINING AND FILLING .

COOLANT PUMP TOOTHED BELT

Special tools and workshop equipment required

1. Insert Tool 12 mm T10360

Removing

Remove small coolant pipe. Refer to SMALL COOLANT PIPE .

Free up the coolant hose -2- and the wiring harness -1-.

Scheme 31

Remove the bolt -arrow- and remove bracket.

Remove the bolt -2- on the bracket for the after-run coolant pump -V51-.

Note. Ignore -1 and arrows-.

Remove the coolant hoses -1 and 2- and lay them aside.

Scheme 32

Remove the bolts -1 through 9- and remove the oil separator.

Scheme 33

Remove the bolts -arrows- and remove the toothed belt guard.

Scheme 34

Remove the bolt on the coolant pump drive gear -1- using a torque wrench V.A.G 1331 and T10360 while counter holding the vibration damper.

Scheme 35

Remove the drive gear -1- and toothed belt -2-.

Installing

1. Tightening specifications, refer to «COOLANT PUMP AND THERMOSTAT ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pump-and-thermostat-assembly-overview) .

Installation is in reverse order of removal, note the following

Note. Replace the drive gear bolt. Replace seals and O-rings. Pay attention to the installed position of the toothed belt drive gear -16- COOLANT PUMP AND THERMOSTAT ASSEMBLY OVERVIEW .

Install the oil separator. Refer to OIL SEPARATOR .

Install after-run coolant pump -V51-. Refer to AFTER-RUN COOLANT PUMP .

Install the small coolant pipe. Refer to SMALL COOLANT PIPE .

Connect the coolant hose with the connector coupling RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

COOLANT PUMP DRIVE SHAFT SEAL

Special tools and workshop equipment required

1. Thrust Piece T10353

Procedure

Remove small coolant pipe. Refer to SMALL COOLANT PIPE .

Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Firmly press a screwdriver -1- on the surface of the seal -2- -arrow B-.

Scheme 36

Pry out the seal -arrow A-.

Clean running and sealing surface.

Coat the sealing surface of the balance shaft -2- with transmission oil.

Scheme 37

Push the seal -1- onto the balance shaft.

1. "Luftseite" or ("Outside") -arrow- must be readable from the outside.

Mount the T10353 on the seal -1- and press it into the cylinder block all the way with the bolt -2- ; when doing this, do not bend the sealing ring.

Scheme 38

Install the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Install the oil separator. Refer to OIL SEPARATOR .

Install after-run coolant pump -V51-. Refer to AFTER-RUN COOLANT PUMP .

Install the small coolant pipe. Refer to SMALL COOLANT PIPE .

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

COOLANT PUMP

Removing

Remove small coolant pipe. Refer to SMALL COOLANT PIPE .

Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Disconnect electrical connector -1- on throttle valve control module -J338-.

Remove bolts -arrows- and remove throttle valve control module.

Disconnect the electrical connector -1- on the engine coolant temperature (ECT) sensor -G62-.

Note. Ignore -2 and arrows-.

Remove bolts -1 to 5-.

Remove the coolant pump from the centering pin and remove the engine oil cooler.

Note. Ignore -arrow-.

Installing

1. Tightening specifications, refer to «COOLANT PUMP AND THERMOSTAT ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pump-and-thermostat-assembly-overview) .

Installation is in reverse order of removal, note the following

Note. Replace seals and O-rings. - Coat the O-rings -4- with coolant; coolant

Scheme 39

Make sure both centering pins are installed in the cylinder block.

Install the connection piece -2- into the engine oil cooler -1-.

Push the coolant pump -3- onto the connection piece and onto the centering pins in the cylinder block.

Tighten bolts -1 to 5-.

Note. If a new coolant pump was installed, then the protective cap -arrow- must be removed.

Install the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Install the oil separator. Refer to OIL SEPARATOR .

Install throttle valve control module. Refer to Description and Operation .

Install the small coolant pipe. Refer to SMALL COOLANT PIPE .

Install after-run coolant pump. Refer to AFTER-RUN COOLANT PUMP .

Connect the coolant hose with the connector coupling RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW .

COOLANT THERMOSTAT

Removing

Drain coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Unclip the lower air guide, to do so disengage the clips -arrows-.

Remove the lower air guide together with the air guide hose.

Loosen the hose clamp -2-.

Remove bolt -4-.

Disconnect electrical connector -arrow-.

Remove the bolt -1- and remove the air guide pipe downward.

Note. Ignore -3-.

Free up the coolant hose -2- and the wiring harness -1-.

Remove the bolt -arrow- and remove bracket.

Remove the bolt -2- on the bracket for the after-run coolant pump.

Note. The after-run coolant pump stays in the installation position. Ignore -1 and arrows-.

Remove the coolant hoses -1 and 2- and lay them aside.

Remove the bolts -1 through 9- and remove the oil separator.

Loosen the nut -2-, remove the bolt -1- and move the support for the intake manifold to the right.

Remove bolts -arrows- and remove connecting pieces.

Scheme 40

Remove the coolant thermostat.

Installing

1. Tightening specifications, refer to «COOLANT PUMP AND THERMOSTAT ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__coolant-pump-and-thermostat-assembly-overview) .

Installation is in reverse order of removal, note the following

Note. Replace seals and O-rings.

Clean O-ring sealing surface.

Coat the O-ring with coolant; coolant

Install the thermostat -4- into the housing -5- for the coolant pump and move it slightly forward -arrow-.

Scheme 41

Carefully mount the connector -3- ; while doing so, insert the centering pin -2- into the guide -1-.

Install the oil separator. Refer to OIL SEPARATOR .

Install the intake manifold support. Refer to Description and Operation .

Install after-run coolant pump. Refer to AFTER-RUN COOLANT PUMP .

Air guides, installing with connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING

Connect the coolant hose with the connector coupling RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

FAN SHROUD

Removing

Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Unclip the lower air guide, to do so disengage the clips -arrows-.

Remove the lower air guide together with the air guide hose.

Remove the bolts -1- from the top.

Scheme 42

Note. Ignore -2 and 3-.

Loosen the hose clamp -2-.

Remove bolt -4-.

Disconnect the connector -arrow- and free up the wire.

Note. Ignore -1 and 3-.

Remove the noise insulation in the center by loosening the fasteners -1 and 2-.

Scheme 43

Remove the air guide hose -1 and 2-.

Remove the bolt -1- and remove the air guide pipe downward.

Note. Ignore -2, 3, 4 and arrow-.

Disconnect electrical connector -2-.

Remove the bolts -3- and remove the fan shroud downward.

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__radiator-and-coolant-fan-overview) .

Installation is in reverse order of removal, note the following

Air guides, installing with connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING

COOLANT FAN -V7- AND COOLANT FAN 2 - V177

Removing

Remove fan shroud. Refer to FAN SHROUD .

Disconnect electrical connector -1-.

Scheme 44

Free up the wires.

Remove nuts -arrows- and remove coolant fan.

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__radiator-and-coolant-fan-overview) .

Installation is in reverse order of removal, note the following

Install fan shroud. Refer to FAN SHROUD .

RADIATOR

Special tools and workshop equipment required

1. Hose Clip Pliers V.A.G 1921

Removing

Note. If there are small impressions on the fins. Refer to COOLERS, CONDENSERS AND CHARGE AIR COOLERS, INSTALLING .

Drain coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove fan shroud. Refer to FAN SHROUD .

Remove air guide hose -arrows-.

Scheme 45

Remove the upper coolant hose -arrow- from the radiator.

Scheme 46

Remove the bolts -1 and 2- and remove the radiator downward.

Scheme 47

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/cooling-fan/#20l-cooling-system-engine-codes-cbfa-ccta__radiator-and-coolant-fan-overview) .

Installation is in reverse order of removal, note the following

Air guides, installing with connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING

Connect the coolant hose with the connector coupling RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW .

Install fan shroud. Refer to FAN SHROUD .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING => Filling .

Scheme 48

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Drip Tray VAS 6208
3. Hose Clip Pliers V.A.G 1921
4. Cooling System Charge Unit VAS 6096
5. Refractometer T10007

Special tools and workshop equipment required

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

1. Cooling System Tester V.A.G 1274 B
2. Adapter V.A.G 1274/9
3. Hose Clamps Up to 25 mm Dia. 3094
4. Hose Clip Pliers V.A.G 1921
5. Insert Tool 12 mm T10360
6. Thrust Piece T10353

See also:
• Removal and Installation
• COOLERS, CONDENSERS AND CHARGE AIR COOLERS, INSTALLING
• HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING
• Description and Operation
• OIL SEPARATOR
• COOLING SYSTEM, DRAINING AND FILLING
• COOLING SYSTEM, CHECKING FOR LEAKS
• FRONT COOLANT PIPES
• SMALL COOLANT PIPE
• COOLANT PUMP AND THERMOSTAT ASSEMBLY OVERVIEW
• ENGINE COOLANT TEMPERATURE SENSOR
• COOLANT PUMP
• COOLANT PUMP TOOTHED BELT
• COOLANT PUMP DRIVE SHAFT SEAL
• COOLANT THERMOSTAT
• COOLANT FAN AND COOLANT FAN 2
• RADIATOR
• RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW
• AFTER-RUN COOLANT PUMP ASSEMBLY OVERVIEW
• COOLANT PIPES ASSEMBLY OVERVIEW
• AFTER-RUN COOLANT PUMP
• FAN SHROUD