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

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 maintanence 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 consequent 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 (-77 °F) (in arctic climatic countries down to approximately -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%. When stronger freeze protection is needed due to the climate, the portion of coolant additive can be increased up to 60% (freeze protection down to approximately -40 °C (-104 °F)). Otherwise the freeze protection and cooling effect are 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 check the freeze protection in the cooling system.

COOLANT MIXTURE RATIO

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

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

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

Attach the coolant hose to the bottom of the radiator RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW .

Vehicles with an EGR Cooler Pump -V400

Attach the lower coolant hose to the EGR cooler pump -arrow-.

Continuation for all Vehicles

Connect the upper coolant hose to the oil cooler -arrow-.

Fill the coolant reservoir on VAS 6096 with at least 8 liters of premixed coolant with the proper mixture ratio

Scheme 10

Attach adapter 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 11

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.

Remove the VAS 6096 from the coolant reservoir.

Fill coolant up to max marking.

Scheme 12

Install air filter housing. Refer to Removal and Installation .

Install the air guides.

Install the air guide hose with the connector coupling CHARGE AIR COOLER ASSEMBLY OVERVIEW => Install the Air Guide Hoses with the Coupling .

Install the noise insulation. Refer to Removal and Installation .

If the vehicle has an auxiliary heater, switch it on for about 30 seconds.

Set the temperature at HI.

Switch the A/C compressor off by pressing the ECON button.

Start the engine and run it 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.

Run the engine at idle until both large coolant hoses on the radiator are warm.

Turn off engine and allow it to cool off.

Check coolant level.

1. The coolant level must be between the min and max markings when the engine is cold.
2. The coolant level may be at the max marking when the engine is warm.

Add more coolant if necessary.

CONNECTION DIAGRAM, COOLANT HOSES

Note. Secure all hose connections with hose clamps appropriate for the model. Arrows on coolant pipes and coolant hoses must line up across from each other.

Scheme 13

1. Coolant Reservoir With sealing cap Pressure relief valve in cap, checking «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-496039-S21649451502012082100000)
2. Cylinder Head and Cylinder Block Change coolant after replacing
3. Cooler for Exhaust Gas Recirculation (EGR) Change coolant after replacing Removing and installing, refer to «HOUSING WITH EGR COOLER»(ref-496087-S15036457132012082100000)
4. Auxiliary Heater
5. Recirculation Pump -V55
6. Heater Core Change coolant after replacing
7. Transmission Oil Cooler For the dual clutch transmission Change coolant after replacing
8. Engine Oil Cooler
9. Engine Preheating Element -Z97- Removing and installing, refer to «ENGINE PREHEATING ELEMENT»(ref-496039-S15682318362012082100000)
10. Radiator Change coolant after replacing
11. 4/2-Way Valve with Thermostat Removing and installing, refer to «4/2-WAY VALVE WITH THERMOSTAT»(ref-496039-S13334157092012082100000)
12. Coolant Pump

Coolant System Components - Intake Side

Scheme 14

1. Lower Reservoir Coolant Hose
2. Upper Reservoir Coolant Hose
3. Bolt 10 Nm
4. Ventilation Pipe
5. Engine Coolant Temperature Sensor -G62
6. Retaining Clip
7. O-ring Replace
8. Transmission Oil Cooler Only on vehicles with the dual clutch transmission
9. Engine Oil Cooler Coolant Supply Hose On vehicles without a transmission fluid cooler On vehicles with a transmission oil cooler: coolant hose return transmission fluid cooler
10. Engine Oil Cooler Coolant Return Hose
11. To the Upper Radiator
12. Bracket for Wiring Harness and Coolant Pipe
13. Coolant Hose To the coolant pipe on the cylinder block
14. Coolant Hoses For the transmission oil cooler Only on vehicles with the dual clutch transmission Installed depending on the vehicle equipment level
15. Coolant Line For the engine preheating element -Z97- Assembly overview «CONNECTION DIAGRAM, COOLANT HOSES»(ref-496039-S30519935122012082100000) Installed depending on the vehicle equipment level
16. Engine Preheating Element -Z97- Assembly overview «CONNECTION DIAGRAM, COOLANT HOSES»(ref-496039-S30519935122012082100000) Removing and installing, refer to «ENGINE PREHEATING ELEMENT»(ref-496039-S15682318362012082100000) Installed depending on the vehicle equipment level
17. Engine Oil Cooler
18. Coolant Thermostat Checking coolant regulator, refer to «THERMOSTAT, CHECKING»(ref-496039-S03426283382012082100000)
19. Connecting Piece
20. Bolt 15 Nm
21. Hose to the Lower Radiator
22. Coolant Pump
23. Bolt 40 Nm

Scheme 15

1. Coolant Pipe for the Engine Preheating Element -Z97
2. Coolant Hose from the Cylinder Block Connection to the Transmission Oil Cooler
3. Coolant Hose from the Transmission Oil Cooler to the Engine Oil Cooler
4. Coolant Hose from he Engine Pre-Warmer Coolant Pipe, to the Engine Preheating Element -Z97
5. Retainer
6. External Power Supply Connecting Wire
7. Left Air Intake Grille -- Air Intake Grille, Removing and Installing, refer to «Removal and Installation»(ref-496068-S28143358632012082100000)
8. Bracket
9. Engine Preheating Element -Z97- Removing and installing, refer to «ENGINE PREHEATING ELEMENT»(ref-496039-S15682318362012082100000)
10. Engine Preheating Element -Z97- Clamp Secured on the bracket
11. Bolt 10 Nm
12. Engine Preheating Element -Z97- Bracket
13. Bracket for Wiring Harness and Coolant Pipe
14. Coolant Hose from the Oil Cooler to the Engine Preheating Element -Z97- Coolant Pipe
15. Engine Preheating Element -Z97- Coolant Hose to the Coolant Pipe on the Cylinder Block

Cooling System Components - Transmission Side

Scheme 16

1. Coolant Supply Hose
2. Coolant Hose to the Ventilation Pipe
3. Exhaust Gas Recirculation Cooler Coolant Return Hose
4. Coolant Return Hose
5. Heat Exchanger Coolant Supply Hose
6. Heat Exchanger Coolant Return Hose
7. Exhaust Gas Recirculation Cooler Coolant Supply Hose
8. Transmission Oil Cooler Coolant Supply Hose
9. Transmission Oil Cooler
10. Transmission Oil Cooler Coolant Return Line

Scheme 17

1. Bolt 15 Nm
2. Coolant pump Removing and installing, refer to «COOLANT PUMP»(ref-496039-S35174255222012082100000)
3. O-ring Replace
4. O-ring Replace
5. 4/2-Way Valve with Thermostat Installed depending on the version Removing and installing, refer to «4/2-WAY VALVE WITH THERMOSTAT»(ref-496039-S13334157092012082100000) The thermostat is located inside the 4/2-way valve and cannot be replaced separately.
6. Bolt 15 Nm
7. Connecting Piece Installed depending on the version
8. Coolant Thermostat Removing and installing, refer to «COOLANT THERMOSTAT»(ref-496039-S10057740732012082100000) Checking, refer to «THERMOSTAT, CHECKING»(ref-496039-S03426283382012082100000) Installed only on the version with connection -7

Scheme 18

1. Grommet Not available individually
2. Sleeve Not available individually
3. Bolt 2.7 Nm
4. Bolt 40 Nm
5. Bracket For the EGR cooler pump -V400
6. Front Coolant Line Removing and installing, refer to «FRONT COOLANT PIPE»(ref-496039-S16801366732012082100000)
7. O-ring Replace
8. Right Coolant Line Removing and installing, refer to «RIGHT COOLANT PIPE»(ref-496039-S33483517642012082100000)
9. O-ring Replace
10. Engine Coolant Temperature Sensor on Radiator -G83- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR»(ref-496039-S42464268932012082100000)
11. Retaining Clip
12. Bolt 9 Nm
13. Nut 9 Nm
14. Bolt 9 Nm
15. Coolant Line
16. Bolt 9 Nm
17. Gasket Replace
18. Connecting Piece
19. Bolt 9 Nm
20. Retaining Clip
21. Engine Coolant Temperature Sensor -G62- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR»(ref-496039-S00017099742012082100000)
22. O-ring Replace
23. Double Bolt 9 Nm
24. Bolt 9 Nm
25. Left Coolant Line Removing and installing, refer to «LEFT COOLANT PIPE»(ref-496039-S35492785272012082100000)
26. Bolt 9 Nm
27. Bolt 40 Nm
28. Bolt 13 Nm
29. EGR Cooler Pump -V400- Removing and installing, refer to «EXHAUST GAS RECIRCULATION COOLER PUMP»(ref-496039-S00521441002012082100000)

THERMOSTAT, CHECKING

Heat up the removed thermostat in water.

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.

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

Scheme 19

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

If pressure falls, search for leaks and correct problem.

Scheme 20

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.

ENGINE PREHEATING ELEMENT

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6362

Removing

Remove the noise insulation -1-. Refer to Removal and Installation .

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

Loosen the hose clamp and remove the coolant hose from the connection -arrow A-.

Scheme 21

Disconnect the connector on the engine preheating element -- -arrow D-.

Loosen the coolant hose clamp and remove the coolant hose from the connection -arrow E-.

Open the clamp -arrow B- and remove the engine preheating element -arrow C- downward.

Installing

Installation is in reverse order of removal, note the following

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

Install the noise insulation. Refer to Removal and Installation .

COOLANT PUMP

Removing

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

Toothed belt, removing. Refer to TOOTHED BELT .

Remove the bolts -1- and the coolant pump -2-.

Scheme 22

Remove O-ring -3-.

Installing

1. Tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT ASSEMBLY OVERVIEW»(ref-496039-S06878524212012082100000) .

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

Clean and smooth the O-ring sealing surface.

Coat the O-ring -3- with coolant.

Insert coolant pump -2-.

1. Installed position: the plug in the housing faces downward.

Install toothed belt (adjust timing) TOOTHED BELT .

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

COOLANT THERMOSTAT

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6362

Removing

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

Remove bolts -arrows-.

Scheme 23

Free up the coolant hose -3-.

Loosen the hose clamp -2-.

Disconnect the connector -1- on the charge air pressure sensor -G31- and then remove the front air guide pipe.

Disconnect the connector -3- on the intake flap motor -V157-.

Scheme 24

Loosen the clamp -4- and remove the air guide hose from the intake flap motor.

Remove the bolt -arrow- on the oil dipstick guide tube.

Note. Ignore -1 and 2-.

Remove the bolts -arrows- and remove the intake flap motor.

Scheme 25

Loosen the clamp and remove the coolant hose -1-.

Scheme 26

Remove bolts -arrows- and remove connecting pieces.

Turn the thermostat -2- clockwise 15° -arrow- and remove it.

Scheme 27

Remove O-ring -1-.

Installing

1. Tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT ASSEMBLY OVERVIEW»(ref-496039-S06878524212012082100000) .

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

Clean and smooth the O-ring sealing surface.

Coat the new O-ring with coolant.

Install the thermostat -3- with the O-ring -2- into the guide -1-.

Scheme 28

Turn the thermostat -1- counter-clockwise until it stops -arrow-.

Scheme 29

Install the intake flap motor. Refer to Removal and Installation .

Install the front air guide pipe. Refer to CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Install the air guide hose with the connector coupling CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Install fan shroud. Refer to FAN SHROUD .

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

4/2-WAY VALVE WITH THERMOSTAT

Removing

Note. The thermostat is inside the 4/2-way valve and cannot be replaced separately.

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

Remove the generator. Refer to [For engine(s) CBRA, BPY, CCTA, CBFA] Removal and Installation and refer to Removal and Installation .

Scheme 30

Remove the throttle valve control module -J338-. Refer to Removal and Installation .

Remove the coolant hoses -A, B and D-.

Scheme 31

Remove bolt -2-.

Remove bolts -1-.

Remove the valve from the cylinder block and pull the connection -C- off the coolant pipe to the left.

Installing

1. Tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT ASSEMBLY OVERVIEW»(ref-496039-S06878524212012082100000) .

Installation is in reverse order of removal, note the following

Note. Replace O-ring.

Install throttle valve control module. Refer to Removal and Installation .

Install the generator. Refer to [For engine(s) CBRA, BPY, CCTA, CBFA] Removal and Installation and refer to Removal and Installation .

ENGINE COOLANT TEMPERATURE SENSOR

Removing

1. Engine cold.

Briefly open the coolant reservoir cap to reduce the residual pressure in the coolant system.

Remove the air filter housing. Refer to Removal and Installation .

Remove the noise insulation -1-. Refer to Removal and Installation .

Remove bolts -arrows-.

Scheme 32

Free up the electrical wires and the hoses on the left air guide pipe using the pry lever - rmv outside mirror80 - 200.

Loosen the clamp -3- and push the left air guide pipe together with the coolant pipe to the left.

Note. Ignore -1, 2, 4 and 5-.

Disconnect the electrical connector -2- on the engine coolant temperature sensor -G62-.

Scheme 33

Note. Lay a cloth under the connection to catch any leaking coolant.

Remove the clamp -1- and then remove the engine coolant temperature sensor.

Note. Ignore -arrows-.

Installing

Installation is in reverse order of removal, note the following

Note. Replace O-rings. To prevent coolant loss, install the new engine coolant temperature sensor immediately.

Install the left air guide pipe. Refer to CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Install the noise insulation. Refer to Removal and Installation .

Install air filter housing. Refer to Removal and Installation .

Check coolant level COOLING SYSTEM, DRAINING AND FILLING .

ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR

Removing

1. Engine cold.

Briefly open the coolant reservoir cap to reduce the residual pressure in the coolant system.

Remove the noise insulation -1-. Refer to Removal and Installation .

Disconnect electrical connector -1- on engine coolant temperature sensor on radiator -G83-.

Scheme 34

Remove the clip -2- and pull the engine coolant temperature sensor on radiator off the coolant pipe.

Installing

Installation is in reverse order of removal, note the following

Note. Replace O-ring. Install the new engine coolant temperature sensor on radiator immediately to prevent coolant loss.

Check coolant level COOLING SYSTEM, DRAINING AND FILLING .

EXHAUST GAS RECIRCULATION COOLER PUMP

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Diameter 3094
2. Hose Clip Pliers VAS 6362

Removing

Remove the noise insulation -1-. Refer to Removal and Installation .

Loosen the hose clamp -2-, lift the retaining clamp -1- and remove the air guide hose.

Remove bolts -arrows-.

Loosen the clamp -2- and move the front air guide pipe to the right.

Note. Ignore -1 and 3-.

Note. Place a cloth under the EGR cooler pump -V400- to catch any coolant leaking out.

Open the clamps -arrows-. Then remove both the coolant hoses and the 3094

Disconnect the connector -2-.

Remove the bolts -1- and remove the EGR cooler pump.

Note. Disregard -arrow-.

Installing

1. Tightening specifications, refer to «COOLANT PIPES, COOLANT TEMPERATURE SENSORS AND COOLANT PUMP ASSEMBLY OVERVIEW»(ref-496039-S29227217062012082100000) .

Installation is in reverse order of removal, note the following

Note. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.

Install the front air guide pipe. Refer to CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Install the air guide hose with the connector coupling CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Install the noise insulation. Refer to Removal and Installation .

Check coolant level COOLING SYSTEM, DRAINING AND FILLING .

FRONT COOLANT PIPE

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6362

Removing

Remove the oil filter bracket. Refer to OIL FILTER BRACKET WITH OIL COOLER .

Remove the battery. Refer to [For engine(s) CBRA, BPY, CCTA, CBFA] Removal and Installation .

Scheme 35

Remove the bolts -arrows- and remove the battery tray -1-.

Scheme 36

Disconnect the connector -3- from the intake flap motor -V157- or from the throttle valve control module -J338-.

Remove the coolant hose by loosening the hose clamp -4-.

Remove the bolt -2- on the EGR pipe.

Note. Ignore -1- and -arrow-.

Remove the bolts -arrows- and then remove the intake flap motor or the throttle valve control module.

Press the release buttons and remove the crankshaft housing ventilation hose -1- from the cylinder head cover.

Scheme 37

Free up the vacuum hoses -arrows- on the air guide pipe.

Loosen the hose clamp -2- and remove the air guide pipe.

Remove the wiring harness from the bracket -arrow-.

Scheme 38

Loosen the hose clamps -arrows- and remove the coolant hoses from the transmission fluid cooler.

Scheme 39

Free up the wiring harness -arrows- and the connector -1- on the bracket.

Scheme 40

Remove the bolts -2 and 5- and -arrows-.

Free up the electrical wires and the hoses on the left air guide pipe using the pry lever - rmv outside mirror80 - 200.

Loosen the hose clamp -3- and remove the left air guide pipe.

Note. Ignore -1 and 4-.

Remove the nuts -1- and bolts -2- and remove the EGR pipe.

Scheme 41

Remove the nut -2- on the vacuum line clamp.

Scheme 42

Remove bolt -1-.

Loosen the union nut by counterholding it with an open-end wrench -3- and remove the oil supply line from the turbocharger connection.

Disconnect the -2- camshaft position sensor -G40- connector.

Scheme 43

Remove the bracket from the front coolant pipe.

Open the clamps -1- and -3- and remove the coolant hoses.

Remove the bolts -arrows- and move the front coolant pipe to the left.

Installing

1. Tightening specifications, refer to «COOLANT PIPES, COOLANT TEMPERATURE SENSORS AND COOLANT PUMP ASSEMBLY OVERVIEW»(ref-496039-S29227217062012082100000) .
2. Tightening specifications, refer to «OIL FILTER BRACKET AND OIL COOLER ASSEMBLY OVERVIEW»(ref-496106-S38227294072012082100000) .

Installation is in reverse order of removal, note the following

Note. Replace seals, gaskets and O-rings. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.

Clean and/or smooth the sealing surfaces of the O-rings.

Coat the O-ring with coolant and slide it onto the front coolant pipe.

Install the front coolant pipe into the coolant pipe.

Install the oil supply line. Refer to -6- OIL FILTER BRACKET AND OIL COOLER ASSEMBLY OVERVIEW .

Install the exhaust gas recirculation pipe EXHAUST TEMPERATURE CONTROL ASSEMBLY OVERVIEW .

Install the left air guide pipe. Refer to CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Install the intake flap motor or the throttle valve control module. Refer to Removal and Installation .

Install the battery tray and the battery. Refer to [For engine(s) CBRA, BPY, CCTA, CBFA] Removal and Installation .

Install the oil filter bracket. Refer to OIL FILTER BRACKET WITH OIL COOLER .

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

LEFT COOLANT PIPE

Special tools and workshop equipment required

1. Pry Lever - Rmv Outside Mirror 80 - 200
2. Hose Clamps Up to 25 mm Diameter 3094
3. Drip Tray VAS 6208
4. Hose Clip Pliers VAS 6362

Removing

Remove the noise insulation -1-. Refer to Removal and Installation .

Remove the air filter housing. Refer to Removal and Installation .

Loosen the hose clamps -arrows- and then remove the coolant hoses and 3094 from the transmission fluid cooler.

Free up the wiring harness -arrows- and the connector -1- on the bracket.

Remove the bolts -2 and 5- and -arrows-.

Free up the electrical wires and the hoses on the left air guide pipe using the 80 - 200.

Loosen the hose clamp -3- and remove the left air guide pipe.

Place VAS 6208 under engine.

Loosen the hose clamps -1- and -4- and remove the coolant hoses and c 3094 from the left coolant pipe.

Remove the left coolant pipe.

Installing

1. Tightening specifications, refer to «COOLANT PIPES, COOLANT TEMPERATURE SENSORS AND COOLANT PUMP ASSEMBLY OVERVIEW»(ref-496039-S29227217062012082100000) .

Installation is in reverse order of removal, note the following

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

Install the left air guide pipe. Refer to CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Install air filter housing. Refer to Removal and Installation .

Install the noise insulation. Refer to Removal and Installation .

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

RIGHT COOLANT PIPE

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Diameter 3094
2. Drip Tray VAS 6208
3. Hose Clip Pliers VAS 6362

Removing

Remove the engine cover -arrows-.

Loosen bolt -1-.

Scheme 44

Remove bolts -2- and nut -3-.

Remove the hose bracket -4- from the fuel filter and then move the fuel filter -7- to the side with the fuel hoses -5- and -6- still connected.

Remove the noise insulation -1-. Refer to Removal and Installation .

Remove the front section of the right front wheel housing liner. Refer to Removal and Installation .

Scheme 45

Place VAS 6208 under engine.

Scheme 46

Disconnect electrical connector -3- on engine coolant temperature sensor on radiator -G83-.

Loosen the hose clamps -arrows- and then remove the coolant hoses and 3094 from the right coolant pipe.

Remove the nut -1- and bolt -2-. Then remove the right coolant pipe.

Installing

1. Tightening specifications, refer to «COOLANT PIPES, COOLANT TEMPERATURE SENSORS AND COOLANT PUMP ASSEMBLY OVERVIEW»(ref-496039-S29227217062012082100000) .

Installation is in reverse order of removal, note the following

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

Install the front section of the front wheel housing liner. Refer to Removal and Installation .

Install the noise insulation. Refer to Removal and Installation .

Install the fuel filter. Refer to Removal and Installation or refer to [For engine(s) BPY, CBFA, CBRA, CCTA] Removal and Installation .

Check coolant level COOLING SYSTEM, DRAINING AND FILLING .

RADIATOR

Special tools and workshop equipment required

1. Drip Tray VAS 6208

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 the bolts -arrows- and the air guide from the lock carrier.

Scheme 47

Lift the clamp -arrow- and remove the left upper coolant hose from the radiator.

Scheme 48

Disconnect the connector -A- on the high pressure sensor -G65- -B-.

Scheme 49

Note. Ignore -C-.

Place VAS 6208 under engine.

Remove the bolts -arrows- on the back of the radiator and remove the radiator upward.

Scheme 50

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(ref-496039-S33964898452012082100000) .

Installation is in reverse order of removal, note the following

Note. Replace the gaskets and O-rings. Secure all hose connections with hose clamps appropriate for the model. Refer to.

Install fan shroud. Refer to FAN SHROUD .

Connect the coolant hose to the connector on the radiator RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

FAN SHROUD

Removing

Remove the engine cover -arrows-.

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

Scheme 51

Release the left and right spring clips -arrow A- and disconnect the lower air guide -2-.

Scheme 52

Move the lower air guide slightly to the rear and disengage the lower air guide -3-.

Disengage the air guide pipe -1- from the lower air guide -arrow B-.

Remove the bolts -upper arrows- on the fan shroud.

Scheme 53

Note. The bolts -lower arrows- will be removed later. Ignore -1-.

Remove the noise insulation -1-. Refer to Removal and Installation .

A3 Cabrio: Remove the noise insulation frame -arrow-. Refer to Removal and Installation .

Scheme 54

Loosen the hose clamp -2-, lift the retaining clamp -1- and remove the air guide hose.

Scheme 55

Disconnect the connector -1-.

Remove the bolts -lower arrows- and remove the fan shroud downward.

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(ref-496039-S33964898452012082100000) .

Installation is in reverse order of removal, note the following

Install the air guide hose with the connector coupling CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Install the noise insulation frame and the noise insulation. Refer to Removal and Installation .

COOLANT FANS

Removing

Remove fan shroud. Refer to FAN SHROUD .

Disconnect the connectors -1- and free them up.

Scheme 56

Remove nuts -arrows- and remove coolant fan.

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN ASSEMBLY OVERVIEW»(ref-496039-S33964898452012082100000) .

Installation is in reverse order of removal, note the following

Note. During installation, all cable ties must be installed at the same location.

Install fan shroud. Refer to FAN SHROUD .

Scheme 57

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Cooling System Charge Unit VAS 6096 with VAS 6096/1
3. Drip Tray VAS 6208
4. Hose Clip Pliers VAS 6362
5. Refractometer T10007

Special tools and workshop equipment required

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Engine Bung Set VAS 6122
2. Cooling System Tester V.A.G 1274 B
3. Adapter V.A.G 1274/8
4. Adapter V.A.G 1274/9
5. Hose Clamps Up to 25 mm Diameter 3094
6. Pry Lever - Rmv Outside Mirror 80 - 200