2.0L - Cooling System - Engine Code(s): Bpy: Other Audi A3 8P facelift

COOLING SYSTEM COMPONENTS, ENGINE SIDE

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

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 .

COOLANT MIXTURE RATIO

1. Coolant (40%) and water (60%) for freeze protection down to -25 °C (-13°F)
2. Coolant (50%) and water (50%) for freeze protection down to -35 °C (-31°F)
3. 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.

1. 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.

1. 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.

1. Needle on the instrument display must still remain in the green region.

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.

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.

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

1. Radiator Removing and installing, refer to «RADIATOR»(ref-496061-S41676559982012082100000) Replace coolant after replacing
2. After-Run Coolant Pump -V51
3. Return Hose from Turbocharger With bypass thermostat in hose
4. Map Controlled Engine Cooling Thermostat -F265- Removing and installing, refer to «COOLANT DISTRIBUTION HOUSING WITH MAP CONTROLLED ENGINE COOLING THERMOSTAT»(ref-496061-S30586258642012082100000)
5. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(ref-496061-S08412897882012082100000)
6. Cylinder Head/Cylinder Block Replace coolant after replacing
7. Turbocharger Removing and installing, refer to «TURBOCHARGER»(ref-496062-S39398486392012082100000)
8. Expansion Tank With sealing cap Pressure relief valve in cap, checking, refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-496061-S22621251002012082100000)
9. Heater Core of Heater Replace coolant after replacing
10. Hose Only vehicles with automatic transmission
11. Transmission Oil Cooler Only vehicles with automatic transmission
12. Hose Only vehicles with automatic transmission With bypass thermostat in hose
13. Coolant Connection
14. Engine Oil Cooler
15. Intake Manifold Removing and installing, refer to «Removal and Installation»(ref-496075-S21350944552012082100000)
16. Hose Only with auxiliary coolant radiator
17. Auxiliary Cooler
18. Hose Only with auxiliary coolant radiator

Scheme 117

1. Bolt 40 Nm
2. Bolt 23 Nm
3. Coolant Pipe
4. Connecting Hose
5. O-ring Replace
6. Connecting Piece
7. Bolt 10 Nm
8. Retaining Clip
9. O-ring Replace
10. Coolant Temperature Sensor -G62
11. Connecting Hose
12. Connecting Piece
13. Connecting Hose
14. Connecting Hose
15. Connecting Hose
16. Coolant Pipe
17. Bolt 9 Nm
18. Connecting Hose
19. Coolant Pipe
20. Bolt 10 Nm
21. Coolant Distribution Housing With coolant thermostat Starts to open 87 °C (188 °F)
22. Bolt 15 Nm
23. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(ref-496061-S08412897882012082100000)
24. Bolt 15 Nm

Scheme 118

1. Nut 3 Nm
2. Coolant Pipe
3. Spring-Type Clip
4. Coolant Pipe To turbocharger
5. Bolt 5 Nm
6. Spring-Type Clip
7. Coolant Hose
8. Bracket
9. Coolant Hose To radiator input
10. Spring-Type Clip
11. After-Run Coolant Pump -V51
12. Bolt 5 Nm
13. Spring-Type Clip
14. Nut 5 Nm

Scheme 119

1. Coolant Fan -V7- Removing and installing, refer to «COOLING SYSTEM COMPONENTS, BODY SIDE»(ref-496061-S21763583602012082100000)
2. Nut 10 Nm
3. Fan Rib
4. Upper Coolant Hose To connection sleeve at cylinder head
5. O-ring Replace if damaged
6. Radiator Removing and installing, refer to «RADIATOR»(ref-496061-S41676559982012082100000) After replacing replace entire amount of coolant
7. O-ring Replace if damaged
8. Lower Coolant Hose To connection for coolant regulator
9. Bolt 5 Nm To charge air cooler
10. Nut 10 Nm
11. Bolt 5 Nm To Radiator
12. Coolant Fan 2 -V177- Removing and installing, refer to «COOLING SYSTEM COMPONENTS, BODY SIDE»(ref-496061-S21763583602012082100000)

COOLING SYSTEM, CHECKING FOR LEAKS

Special tools and workshop equipment required

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

Test Conditions

1. Engine at operating temperature.

Test Sequence

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.

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

COOLANT PIPES

Special tools and workshop equipment required

1. 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

1. For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(ref-496061-S08910519212012082100000)

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

1. For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(ref-496061-S08910519212012082100000)

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

1. Drip Tray VAS 6208
2. Hose Clip Pliers VAS 5024 A

Removing

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

1. For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(ref-496061-S08910519212012082100000)

Clean and/or smooth O-ring sealing surface.

Coat new O-ring -3- with coolant.

Insert coolant pump -2-.

1. 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

1. Drip Tray VAS 6208
2. Hose Clip Pliers VAS 5024 A

Removing

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

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

1. For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(ref-496061-S33269633372012082100000)

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

1. 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

1. For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(ref-496061-S33269633372012082100000)

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

1. For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(ref-496061-S33269633372012082100000)

Install fan shroud. Refer to FAN SHROUD .

Scheme 138

Special tools and workshop equipment required

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

Scheme 139

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 140

1. Hose Clip Pliers VAS 5024A