COOLING SYSTEM COMPONENTS, ENGINE SIDE
| WARNING | Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened. |
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.
COOLING SYSTEM COMPONENTS, BODY SIDE
| WARNING | Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system. |
| WARNING | Risk of injury from coolant fan starting by itself. Before working in fan shroud area, disconnect electrical connectors. |
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. If there are small impressions on the fins. Refer to COOLERS, CONDENSERS AND CHARGE AIR COOLERS .
COOLING SYSTEM, DRAINING AND FILLING
Special tools and workshop equipment required
- Adapter V.A.G 1274/8
- Drip Tray VAS 6208
- Hose Clip Pliers V.A.G 1921
- Cooling System Charge Unit VAS 6096
- Refractometer T10007
Draining
Note. Drained coolant must be stored in a clean container for disposal or reuse.
| WARNING | Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened. |
Open cap of coolant expansion tank.
Remove noise insulation. Refer to Removal and Installation .
Place the VAS 6208 under engine.
Drain the coolant, by pulling off the lower coolant hose -arrows-.
Scheme 112
Filling
Note. The cooling system is filled year-round with a mixture of water and coolant additive. Mixture ratio COOLING SYSTEM, DRAINING AND FILLING . Only use coolant according to the manufacturers maintenance information. 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 down to approximately -25 °C (-13°F) (in arctic climatic countries down to approximately -35 °C (-31°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 (-40°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.
Push the lower coolant hose onto the radiator -arrow-.
Fill coolant reservoir of VAS 6096 with at least 8 liters of pre-mixed coolant with correct mixture ratio COOLING SYSTEM, DRAINING AND FILLING => Coolant Mixture Ratio .
Scheme 113
COOLANT MIXTURE RATIO
- Coolant (40%) and water (60%) for freeze protection down to -25 °C (-13°F)
- Coolant (50%) and water (50%) for freeze protection down to -35 °C (-31°F)
- Coolant (60%) and water (40%) for freeze protection down to -40 °C (-40°F)
Install V.A.G 1274/8 on expansion tank.
Assemble the VAS 6096 on the V.A.G 1274/8.
Place air outlet hose -1- into a small container -2-. (A small amount of coolant is drawn off which should be reserved with the discharged air.)
Close both valves -A- and -B- (lever perpendicular to direction of flow).
Connect hose -3- to pressurized air.
- Pressure: 6 to 10 bar pressure
Open valve -B- (lever in direction of flow).
Scheme 114
A vacuum is created in the cooling system by the suction jet pump.
- Needle on the instrument display must travel into the green region.
Briefly open valve -A- (lever in direction of flow), so that the hose of the VAS 6096 is filled with coolant.
Close valve -A- again.
Let valve -B- remain open for another 2 minutes.
A further vacuum is created in the cooling system by the suction jet pump.
- Needle on the instrument display must still remain in the green region.
Close valve -B-.
- 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.
If needle stands below the green region, repeat procedure.
If the vacuum decreases, cooling system is leaking.
Disconnect pressurized air hose.
Open valve -A-.
The vacuum in the cooling system causes coolant to be extracted from the VAS 6096; cooling system is filled.
Check coolant level and add coolant up to max-marking.
Scheme 115
Start engine, allow it to run at approximately 1500 RPM for a max. of 2 minutes and fill coolant up to overflow hole of expansion tank.
Close expansion tank.
Allow engine to run until fan turns on.
| WARNING | Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened. |
Check coolant level and fill if necessary. With engine at operating temperature, coolant level must be at max. marking, with engine cold, it must be between min. and max. marking.
Shut off engine.
Scheme 116
- Radiator Removing and installing, refer to «RADIATOR»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__radiator) Replace coolant after replacing
- After-Run Coolant Pump -V51
- Return Hose from Turbocharger With bypass thermostat in hose
- Map Controlled Engine Cooling Thermostat -F265- Removing and installing, refer to «COOLANT DISTRIBUTION HOUSING WITH MAP CONTROLLED ENGINE COOLING THERMOSTAT»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__coolant-distribution-housing-with-map-controlled)
- Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__coolant-pump)
- Cylinder Head/Cylinder Block Replace coolant after replacing
- Turbocharger Removing and installing, refer to «TURBOCHARGER»(/audi/a3/8p-2004-2008/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-bpy)
- Expansion Tank With sealing cap Pressure relief valve in cap, checking, refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__cooling-system-checking-for-leaks)
- Heater Core of Heater Replace coolant after replacing
- Hose Only vehicles with automatic transmission
- Transmission Oil Cooler Only vehicles with automatic transmission
- Hose Only vehicles with automatic transmission With bypass thermostat in hose
- Coolant Connection
- Engine Oil Cooler
- Intake Manifold Removing and installing, refer to «Removal and Installation»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy)
- Hose Only with auxiliary coolant radiator
- Auxiliary Cooler
- Hose Only with auxiliary coolant radiator
Scheme 117
- Bolt 40 Nm
- Bolt 23 Nm
- Coolant Pipe
- Connecting Hose
- O-ring Replace
- Connecting Piece
- Bolt 10 Nm
- Retaining Clip
- O-ring Replace
- Coolant Temperature Sensor -G62
- Connecting Hose
- Connecting Piece
- Connecting Hose
- Connecting Hose
- Connecting Hose
- Coolant Pipe
- Bolt 9 Nm
- Connecting Hose
- Coolant Pipe
- Bolt 10 Nm
- Coolant Distribution Housing With coolant thermostat Starts to open 87 °C (188 °F)
- Bolt 15 Nm
- Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__coolant-pump)
- Bolt 15 Nm
Scheme 118
- Nut 3 Nm
- Coolant Pipe
- Spring-Type Clip
- Coolant Pipe To turbocharger
- Bolt 5 Nm
- Spring-Type Clip
- Coolant Hose
- Bracket
- Coolant Hose To radiator input
- Spring-Type Clip
- After-Run Coolant Pump -V51
- Bolt 5 Nm
- Spring-Type Clip
- Nut 5 Nm
Scheme 119
- Coolant Fan -V7- Removing and installing, refer to «COOLING SYSTEM COMPONENTS, BODY SIDE»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__cooling-system-components-body-side)
- Nut 10 Nm
- Fan Rib
- Upper Coolant Hose To connection sleeve at cylinder head
- O-ring Replace if damaged
- Radiator Removing and installing, refer to «RADIATOR»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__radiator) After replacing replace entire amount of coolant
- O-ring Replace if damaged
- Lower Coolant Hose To connection for coolant regulator
- Bolt 5 Nm To charge air cooler
- Nut 10 Nm
- Bolt 5 Nm To Radiator
- Coolant Fan 2 -V177- Removing and installing, refer to «COOLING SYSTEM COMPONENTS, BODY SIDE»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy__cooling-system-components-body-side)
FASTENER TIGHTENING SPECIFICATIONS
| Component | Bolt Size | Nm |
|---|---|---|
| After-Run Coolant Pump | 5 | |
| Connecting Piece | 10 | |
| Coolant Distribution Housing | 15 | |
| Coolant Fan, Nut | 10 | |
| Coolant Pipe (1) | ||
| 23 | ||
| 40 | ||
| Coolant Pipe (2) | 9 | |
| Coolant Pipe (3) | 10 | |
| Coolant Pipe, Nut | 3 | |
| Coolant Pipe to Turbocharger | 5 | |
| Coolant Pump | 15 | |
| Fan Rib | 5 | |
| Radiator | 5 | |
| (1) For bolt tightening clarification, refer to COOLING SYSTEM OVERVIEW and see items -1 and 2- (2) For bolt tightening clarification, refer to COOLING SYSTEM OVERVIEW and see item -16- (3) For bolt tightening clarification, refer to COOLING SYSTEM OVERVIEW and see item -19- () For bolt tightening clarification, refer to AFTER-RUN COOLANT PUMP OVERVIEW and see item -2 | ||
| (1) | For bolt tightening clarification, refer to COOLING SYSTEM OVERVIEW and see items -1 and 2 |
| (2) | For bolt tightening clarification, refer to COOLING SYSTEM OVERVIEW and see item -16 |
| (3) | For bolt tightening clarification, refer to COOLING SYSTEM OVERVIEW and see item -19 |
| () | For bolt tightening clarification, refer to AFTER-RUN COOLANT PUMP OVERVIEW and see item -2 |
COOLING SYSTEM, CHECKING FOR LEAKS
Special tools and workshop equipment required
- Cooling System Tester V.A.G 1274
- Adapter V.A.G 1274/8
- Adapter V.A.G 1274/9
Test Conditions
- Engine at operating temperature.
Test Sequence
| WARNING | Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened. |
Open cap of coolant expansion tank.
Attach V.A.G 1274 with V.A.G 1274/8 to expansion tank.
Scheme 120
Generate a positive pressure of approximately 1.0 bar using hand pump of cooling system tester.
If pressure decreases, search for leaking areas and repair the malfunction.
Pressure Relief Valve in Cap, Checking
Attach V.A.G 1274 with V.A.G 1274/9 to cap.
Scheme 121
Operate hand pump.
- The pressure release valve must open at 1.4 to 1.6 bar
COOLANT PIPES
Special tools and workshop equipment required
- Hose Clip Pliers VAS 5024A
Removing
Remove the engine cover and air filter. Refer to Removal and Installation .
Remove pipe -A- and hose -B- -arrows-.
Scheme 122
Remove noise insulation. Refer to Removal and Installation .
Remove the air duct -1 and 2- for charge air cooler.
Scheme 123
Loosen clamp -2-.
Scheme 124
Disconnect the connector -4-.
Remove the nut -3- and bolt -1-.
Remove intake tube downward and out.
Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .
Disconnect electrical connectors -arrow-.
Scheme 125
Disconnect coolant hoses from coolant pipes -arrows-.
Scheme 126
Disconnect hose -A- and remove bolt -B-. Remove front coolant pipe.
Scheme 127
Disengage connector -A- from bracket, disconnect hose -B- and remove bolts -C-. Remove rear coolant pipe.
Scheme 128
Installing
Install in reverse order of removal. Note the following
- For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy)
Note. Always replace gaskets and seals. Secure all hose connections using hose clamps appropriate for the model
Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .
COOLANT DISTRIBUTION HOUSING WITH MAP CONTROLLED ENGINE COOLING THERMOSTAT
Removing
Remove the generator. Refer to Removal and Installation or refer to Removal and Installation .
Disconnect coolant pipes. Refer to COOLANT PIPES .
Pull the coolant hose -2- off from coolant distribution housing, thereby pull out retaining clip -1-.
Scheme 129
Remove bolts -arrows- and remove coolant distribution housing with map controlled engine cooling thermostat -F265- from engine.
Scheme 130
Installing
Install in reverse order of removal. Note the following
- For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy)
Note. Always replace gaskets and seals. Secure all hose connections using hose clamps appropriate for the model type
Clean sealing surface for O-ring.
Replace the O-ring and coat with coolant.
Install generator. Refer to Removal and Installation or refer to Removal and Installation .
Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .
COOLANT PUMP
Special tools and workshop equipment required
- Drip Tray VAS 6208
- Hose Clip Pliers VAS 5024 A
Removing
| WARNING | Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened. |
Open cap of coolant expansion tank.
Remove the engine cover and air filter. Refer to Removal and Installation .
Remove noise insulation. Refer to Removal and Installation .
Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .
Remove toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD or TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .
Remove the coolant pump bolts -1- and then remove the coolant pump -2-.
Scheme 131
Remove O-ring -3-.
Installing
Install in reverse order of removal. Note the following
- For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy)
Clean and/or smooth O-ring sealing surface.
Coat new O-ring -3- with coolant.
Insert coolant pump -2-.
- Installation position: Sealing plug in housing points downward.
Install toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD or TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .
Install the ribbed belt. Refer to RIBBED BELT .
Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .
RADIATOR
Special tools and workshop equipment required
- Drip Tray VAS 6208
- Hose Clip Pliers VAS 5024 A
Removing
Note. If there are small impressions on the fins. Refer to COOLERS, CONDENSERS AND CHARGE AIR COOLERS .
| WARNING | Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened. |
Open cap of coolant expansion tank.
Disconnect the intake connection -1- using VAS 5024 A.
Scheme 132
Remove intake connection at lock carrier -arrows- and remove it.
Remove the bolts -1- from above.
Scheme 133
Remove noise insulation. Refer to Removal and Installation .
Remove the air duct -1 and 2- for charge air cooler.
Disconnect the connector -2-.
Remove bolts -3- and remove the fan shroud downward and off.
Place the VAS 6208 under engine.
Drain the coolant, by pulling off the lower coolant hose -arrows-.
Pull the connector -1- at left longitudinal member out of the retainer.
Scheme 134
Remove retainer for cable connector -2-.
Disconnect the connector from the hood latch -1
Scheme 135
Disconnect upper coolant hose from radiator -2-.
Remove bolts -arrows- on rear side of radiator.
Scheme 136
Lift radiator slightly and remove upward and off.
Installing
Install in reverse order of removal. Note the following
- For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy)
Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .
Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .
FAN SHROUD
Special tools and workshop equipment required
- Hose Clip Pliers V.A.G 1921
Removing
Remove the bolts -1- from above.
Remove noise insulation. Refer to Removal and Installation .
Remove the air duct -1 and 2- for charge air cooler.
Disconnect the connector -2-.
Remove bolts -3- and remove the fan shroud downward and off.
Installing
Install in reverse order of removal. Note the following
- For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy)
Air guide pipes with connector, installing HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .
COOLANT FANS
Removing
Remove fan shroud. Refer to FAN SHROUD .
Disconnect the connector -1-.
Scheme 137
Free up the cables.
Remove nuts -arrows- and remove fans.
Installing
Install in reverse order of removal. Note the following
- For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/a3/8p-2004-2008/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy)
Install fan shroud. Refer to FAN SHROUD .
Scheme 138
Special tools and workshop equipment required
- Cooling System Tester V.A.G 1274
- Adapter V.A.G 1274/8
- Adapter V.A.G 1274/9
Scheme 139
Special tools and workshop equipment required
- Adapter V.A.G 1274/8
- Drip Tray VAS 6208
- Hose Clip Pliers V.A.G 1921
- Cooling System Charge Unit VAS 6096
- Refractometer T10007
Special tools and workshop equipment required
Scheme 140
- Hose Clip Pliers VAS 5024A
See also:
• COOLERS, CONDENSERS AND CHARGE AIR COOLERS
• Removal and Installation
• TURBOCHARGER
• Removal and Installation
• Removal and Installation
• Removal and Installation
• TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD
• TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD
• RIBBED BELT
• HOSE CONNECTIONS WITH CONNECTOR COUPLINGS
• COOLING SYSTEM, DRAINING AND FILLING
• RADIATOR
• COOLANT DISTRIBUTION HOUSING WITH MAP CONTROLLED ENGINE COOLING THERMOSTAT
• COOLANT PUMP
• COOLING SYSTEM, CHECKING FOR LEAKS
• COOLING SYSTEM COMPONENTS, BODY SIDE
• COOLING SYSTEM OVERVIEW
• COOLANT PIPES
• FAN SHROUD