2.0l - Cooling System - Engine Code(s): Cdma (roadster) Audi TT RS 8J

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

Note. Collect draining coolant in a clean container for disposal or reuse.

Open the coolant reservoir cap.

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

Scheme 395

Place the VAS 6208 under engine.

Remove coolant hose downward from radiator -arrow- and allow coolant to drain.

Scheme 396

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

Scheme 397

Note. The illustration shows the coolant hose on a vehicle with an S-Tronic transmission.

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 . 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 increased freeze protection is needed because of the climate, the amount of G12+ can be increased, but only up to 60% to provide freeze protection to about -40 °C (-40 °F). Otherwise the freeze protection and cooling effectiveness will be reduced. Only use clean drinking water for mixing coolant. Do not reuse coolant if the radiator, heat exchanger, cylinder head or head seal or cylinder block were replaced. Dirty coolant may not be used again. Use the refractometer T10007 to determine the level of freeze protection in the coolant system.

Connect the coolant hose to the connector on the radiator. (Scheme 406)

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

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 .

Scheme 398

Coolant Mixture Ratio

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

1. Coolant (50%) and water (50%) for freeze protection down to -35 °C (-31 °F)

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

Install the 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. Pressure: 6 to 10 bar pressure.

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

Scheme 399

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 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 400

Set the temperature at "HI".

Press the ECON button to turn off the A/C compressor.

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 cap on coolant expansion tank.

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

Turn off engine and allow it to cool off.

Install the noise insulation. Refer to Removal and Installation .

Check the 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.

COOLANT HOSE CONNECTION DIAGRAM

Note. Arrows on coolant pipes and ends of coolant hoses must align when installing.

Scheme 401

1. Radiator Change coolant after replacing
2. After-Run Coolant Pump -V51
3. Coolant Thermostat with Housing
4. Coolant Pump
5. Cylinder Head and Cylinder Block Change coolant after replacing
6. Turbocharger
7. Coolant Reservoir With cover and pressure relief valve Pressure relief valve, checking «COOLING SYSTEM, CHECKING FOR LEAKS»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__cooling-system-checking-for-leaks)
8. Heater Core Change coolant after replacing
9. Coolant Connection
10. Oil Cooler Change coolant after replacing
11. Intake Manifold

COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW

Scheme 402

1. Bolt 15 Nm
2. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__coolant-pump)
3. O-ring Replace
4. Coolant Thermostat with Housing Removing and installing, refer to «COOLANT THERMOSTAT WITH HOUSING»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__coolant-thermostat-with-housing)
5. O-ring Replace
6. Front Coolant Pipe 1 Removing and installing, refer to «FRONT COOLANT PIPES 1 AND 2»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__front-coolant-pipes-1-and-2)
7. Bolt Tightening specifications COOLANT PIPES OVERVIEW
8. Engine Coolant Temperature Sensor on Radiator -G83- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__engine-coolant-temperature-sensor-on-radiator)
9. O-ring Replace
10. Retaining Clip
11. Coolant Hose With a mount for the engine coolant temperature sensor on radiator
12. O-ring Replace
13. Bolt 9 Nm
14. O-ring Replace

Scheme 403

1. Right Front Coolant Pipe Removing and installing, refer to «RIGHT FRONT COOLANT PIPE»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__right-front-coolant-pipe)
2. Bolt 6 Nm
3. Bolt 40 Nm
4. Bolt 23 Nm
5. Coolant Ventilation Line
6. Bolt 9 Nm
7. O-ring Replace
8. Bolt 9 Nm
9. Retaining Clip
10. Engine Coolant Temperature Sensor -G62- Removing and installing, refer to «ENGINE COOLANT TEMPERATURE SENSOR»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__engine-coolant-temperature-sensor)
11. O-ring Replace
12. Coolant Connection
13. Front Coolant Pipe 1 Removing and installing, refer to «FRONT COOLANT PIPES 1 AND 2»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__front-coolant-pipes-1-and-2)
14. Bolt 9 Nm
15. Front Coolant Pipe 2 Removing and installing, refer to «FRONT COOLANT PIPES 1 AND 2»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__front-coolant-pipes-1-and-2)
16. Bolt 9 Nm
17. Bolt 9 Nm
18. O-ring Replace
19. Nut 9 Nm

Scheme 404

1. Bracket
2. Bolt 9 Nm
3. Coolant Hose
4. Coolant Hose
5. Bolt 4 Nm
6. After-Run Coolant Pump -V51- Removing and installing, refer to «AFTER-RUN COOLANT PUMP»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__after-run-coolant-pump)

Scheme 405

1. Coolant Fan -V7- Removing and installing, refer to «COOLANT FAN AND COOLANT FAN 2»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__coolant-fan-and-coolant-fan-2)
2. Nut 10 Nm
3. Fan Rib Removing and installing, refer to «FAN SHROUD»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__fan-shroud)
4. Upper Coolant Hose Connect to the radiator (Scheme 406)
5. O-ring Replace
6. Radiator Removing and installing, refer to «RADIATOR»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__radiator) After replacing, replace entire amount of coolant
7. O-ring Replace
8. Lower Coolant Hose Connect to the radiator (Scheme 406)
9. Bolt 5 Nm
10. Nut 10 Nm
11. Bolt 5 Nm
12. Coolant Fan 2 -V177- Removing and installing, refer to «COOLANT FAN AND COOLANT FAN 2»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__coolant-fan-and-coolant-fan-2)

Scheme 406

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

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

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

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

FASTENER TIGHTENING SPECIFICATIONS

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 the coolant reservoir cap.

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

Scheme 407

Generate approximately 1 bar pressure with cooling system tester hand pump.

If pressure falls, search for leaks and correct problem.

Scheme 408

Attach THE 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 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 front noise insulation -1-. Refer to Removal and Installation .

Disconnect electrical connector -2- on Engine Coolant Temperature (ECT) Sensor on Radiator -G83-.

Scheme 409

Note. Lay a cloth below to catch escaping coolant.

Remove the retaining clip -1- and the engine coolant temperature (ECT) sensor.

Installing

Installation is done is reverse order, observe the following

Note. Replace O-ring. Insert the new engine coolant temperature (ECT) sensor immediately in the connection to prevent coolant loss.

Install the noise insulation. Refer to Removal and Installation .

Check the coolant level COOLING SYSTEM, DRAINING AND FILLING .

COOLANT PUMP

Special tools and workshop equipment required

1. Drip Tray VAS 6208

Removing

Toothed belt, removing. Refer to TOOTHED BELT .

Place the VAS 6208 under the engine.

Remove the bolts -1- and coolant pump -2- with the O-ring -3-.

Scheme 410

Installing

1. Tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__coolant-pump-and-coolant-thermostat-with) .

Installation is done is reverse order, observe the following

Note. Replace O-ring.

Clean and smooth the O-ring sealing surface.

Coat the O-ring -3- with coolant additive.

Insert coolant pump -2-.

1. Installed position: the sealing plugs in the housing face downward.

Install toothed belt (adjust timing) TOOTHED BELT .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

COOLANT THERMOSTAT WITH HOUSING

Removing

Remove generator. Refer to [For transmission(s) 02E] Removal and Installation .

Remove the coolant pipes. Refer to FRONT COOLANT PIPES 1 AND 2 .

Disconnect the connector -2- from the Engine Coolant Temperature (ECT) Sensor on Radiator -G83-.

Note. Ignore -1-.

Raise the retaining clip and remove the coolant hose -arrow- from the coolant thermostat with housing.

Scheme 411

Remove the bolts -arrows- and the coolant thermostat with the housing.

Scheme 412

Installing

Installation is carried out in the reverse order while noting the following

1. Tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster__coolant-pump-and-coolant-thermostat-with) .

Note. Replace seals and sealing rings.

Clean and smooth the O-ring sealing surface.

Coat the O-ring with coolant additive.

Install the coolant pipes. Refer to FRONT COOLANT PIPES 1 AND 2 .

Install generator. Refer to [For transmission(s) 02E] Removal and Installation .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

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 engine cover -arrows-.

Scheme 413

Disconnect the connector -1- from the Engine Coolant Temperature (ECT) Sensor -G62-.

Scheme 414

Note. Lay a cloth below to catch escaping coolant. Ignore -2-.

Remove the retaining clip and the engine coolant temperature sensor.

Installing

Installation is done is reverse order, observe the following

Note. Replace O-ring. To prevent coolant loss, immediately insert new engine coolant temperature sensor in support.

Check the coolant level COOLING SYSTEM, DRAINING AND FILLING .

FRONT COOLANT PIPES 1 AND 2

Special tools and workshop equipment required

1. Pry Lever - Rmv Outside Mirror 80 - 200
2. Hose Clip Pliers V.A.G 1921
3. Hose Clip Pliers VAS 6340

Removing

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

Remove fan shroud. Refer to FAN SHROUD .

Remove the coolant hose by loosening the hose clamp -1-.

Disconnect the connector -2- from the Mass Airflow (MAF) Sensor -G70-.

Detach upper section of air filter housing -arrow- and remove air filter insert.

Remove the bolts -arrows- and the lower section of the air filter housing.

Scheme 415

Disconnect the connector -3-.

Scheme 416

Remove bolt -arrow-.

Remove the hose -2-.

Loosen the hose clamp -1- and remove the turbocharger recirculation valve -N249- with the hose attached -4- from the air guide pipe and lay it aside.

Disconnect the connector -arrow- on the charge air pressure sensor -G31-.

Scheme 417

Remove the bolt -1- and nut -4-.

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

Note. Ignore -3-.

Remove the coolant hoses -arrows- from the coolant pipes.

Scheme 418

Remove the coolant hose -A-.

Scheme 419

Remove the bolt -B- and the front coolant pipe 2.

Press the bracket with the electrical connectors -A- off the coolant pipe with the 80 - 200.

Scheme 420

Remove the coolant hose -B-.

Remove the bolts -C- and the front coolant pipe 1.

Installing

1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster) .

Installation is done in reverse order, observe the following

Note. Replace seals and sealing rings. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

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

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

Install fan shroud. Refer to FAN SHROUD .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

RIGHT FRONT COOLANT PIPE

Special tools and workshop equipment required

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

Removing

Remove the engine cover -arrows-.

Clamp off the coolant hose -arrow- with the 3094 and remove.

Scheme 421

Clamp off the coolant hose -arrow- with 3094 and remove.

Scheme 422

Note. Lay a cloth below to catch escaping coolant.

Remove the bolt and nut -arrows- and the right front coolant pipe.

Installing

1. Tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster) .

Installation is done is reverse order, observe the following

Check the coolant level COOLING SYSTEM, DRAINING AND FILLING => Check the coolant level. .

AFTER-RUN COOLANT PUMP

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094

Removing

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

Disconnect the connector -1-.

Scheme 423

Note. Lay a cloth below to catch escaping coolant.

Clamp off the coolant hoses -arrow- with the 3094 and remove.

Remove the bolt -3- and the after-run coolant pump -V51-.

Note. Ignore -2 and 4-.

Installing

1. Tightening specifications, refer to «AFTER-RUN COOLANT PUMP OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster) .

Installation is done is reverse order, observe the following

Install the noise insulation. Refer to Removal and Installation .

Check the coolant level COOLING SYSTEM, DRAINING AND FILLING .

RADIATOR

Removing

Note. When assembled correctly, radiator and condenser can show slight impressions on the fins. It is not damage. Radiators or condensers should not be replaced because of slight impressions like these.

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

Remove fan shroud. Refer to FAN SHROUD .

Remove the upper coolant hose -arrow- from the radiator by removing the retaining clip.

Scheme 424

Remove the bolts -arrows- on the rear side of the radiator.

Scheme 425

Lift radiator slightly and remove upward and off.

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster) .

Installation is done in reverse order, observe the following

Install fan shroud FAN SHROUD .

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

FAN SHROUD

Removing

Remove the bolts -arrows- and air guide.

Scheme 426

Disconnect the connector -1-.

Scheme 427

Remove the bolts -arrows- and remove the fan shroud upward.

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster) .

Install in reverse order of removal.

COOLANT FAN AND COOLANT FAN 2

Removing

Remove fan shroud. Refer to FAN SHROUD .

Disconnect the connector -1-.

Scheme 428

Free up electrical wires.

Remove nuts -arrows- and remove coolant fan.

Installing

1. Tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-cdma-roadster) .

Installation is done is reverse order, observe the following

Install fan shroud. Refer to FAN SHROUD .

Scheme 429

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 430

Scheme 431

Scheme 432

Scheme 433

Scheme 434

1. Cooling System Tester V.A.G 1274 B
2. Adapter V.A.G 1274/9
3. Pry Lever - Rmv Outside Mirror 80 - 200
4. Hose Clip Pliers VAS 6340
5. Hose Clamps Up to 25 mm Dia. 3094

See also:
• Removal and Installation
• TOOTHED BELT
• [For transmission(s) 02E] Removal and Installation
• CHARGE AIR COOLER OVERVIEW
• Removal and Installation
• COOLING SYSTEM, DRAINING AND FILLING
• COOLING SYSTEM, CHECKING FOR LEAKS
• COOLANT PUMP
• COOLANT THERMOSTAT WITH HOUSING
• FRONT COOLANT PIPES 1 AND 2
• ENGINE COOLANT TEMPERATURE SENSOR ON RADIATOR
• RIGHT FRONT COOLANT PIPE
• ENGINE COOLANT TEMPERATURE SENSOR
• AFTER-RUN COOLANT PUMP
• COOLANT FAN AND COOLANT FAN 2
• FAN SHROUD
• RADIATOR
• COOLANT PIPES OVERVIEW
• COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW