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2.0l - Cooling System - Engine Code(s): Bpy (coupe) Audi TT 8J

Cooling Fan 32 illustrations ~2352 words

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

WARNINGCover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Remove center noise insulation fasteners -1 through 4-.

Scheme 48

Scheme 48
Scheme 48

Remove noise insulation frame -arrow-.

Scheme 49

Scheme 49
Scheme 49

Place the VAS 6208 under engine.

Drain the coolant, by pulling off the lower coolant hose -arrows-.

Scheme 50

Scheme 50
Scheme 50

Filling

Note. The cooling system is filled all year round with a mixture of frost and corrosion protection additives and water. Only use one of the frost and corrosion additives approved for this vehicle. 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. Frost and corrosion protection additives prevent freezing and corrosion damage and scaling. They also raise the boiling point. For this reason the system must be filled all year round with frost and corrosion protection additives. 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. The 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% (freeze protection to about -40 °C (-40 °F). Otherwise the freeze protection and cooling effectiveness will be reduced. Only clean drinking water may be used for mixing coolant. If the radiator, heater core, cylinder head and cylinder head gasket or cylinder block is replaced, completely replace the engine coolant. Dirty coolant may not be used again. Secure all hose connections with hose clamps appropriate for the model. 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 the VAS 6096 with at least 8 liters of pre-mixed coolant with correct mixture ratio

Scheme 51

Scheme 51
Scheme 51
  1. Coolant freeze and corrosion protection additive (40%) and water (60%) for freeze protection up to -25 °C (-13 °F).
  2. Coolant freeze and corrosion protection additive (50%) and water (50%) for freeze protection up to -35 °C (-31 °F).
  3. For coolant freeze and corrosion protection additive.

Install the V.A.G 1274/8 on expansion tank.

Assemble the VAS 6096 on 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 positive pressure.

Open valve -B- (lever in direction of flow).

Scheme 52

Scheme 52
Scheme 52

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 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 53

Scheme 53
Scheme 53

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.

WARNINGCover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

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 54

Scheme 54: COOLANT HOSE CONNECTION DIAGRAM
Scheme 54: COOLANT HOSE CONNECTION DIAGRAM
  1. Radiator Removing and installing, refer to «RADIATOR»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__radiator) Replace coolant after replacing
  2. After-Run Coolant Pump -V51
  3. Map Controlled Engine Cooling Thermostat -F265- Removing and installing, refer to «COOLANT DISTRIBUTION HOUSING WITH MAP CONTROLLED ENGINE COOLING THERMOSTAT»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__coolant-distribution-housing-with-map-controlled)
  4. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__coolant-pump)
  5. Cylinder Head/Cylinder Block Replace coolant after replacing
  6. Turbocharger Removing and installing, refer to «TURBOCHARGER»(/audi/tt/8j-2006-2010/remont/blowers-superchargers-turbochargers/#20l-turbocharger-supercharger-engine-codes-bpy-coupe-as-of-102010)
  7. Expansion Tank With cap Pressure relief valve in cap, checking, refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__cooling-system-checking-for-leaks)
  8. Heater Core of Heater Replace coolant after replacing
  9. Coolant Connection
  10. Engine Oil Cooler
  11. Intake Manifold Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/fuel-system/#20l-fuel-injection-system-engine-codes-bpy-cdma-coupe__removal-and-installation)

COOLING SYSTEM OVERVIEW

WARNINGCover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

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.

Scheme 55

Scheme 55
Scheme 55
  1. Bolt 40 Nm
  2. Bolt 30 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. Engine Coolant Temperature Sensor -G62
  11. Connecting Hose
  12. Connecting Piece
  13. Connecting Hose
  14. Connecting Hose
  15. Connecting Hose
  16. Coolant Pipe
  17. Bolt 5 Nm
  18. Connecting Hose
  19. Coolant Pipe
  20. Bolt 5 Nm
  21. Coolant Distribution Housing With coolant thermostat Starts to open 87 °C (188.60 °F)
  22. Bolt 15 Nm
  23. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__coolant-pump)
  24. Bolt 15 Nm

Scheme 56

Scheme 56: AFTER-RUN COOLANT PUMP OVERVIEW
Scheme 56: AFTER-RUN COOLANT PUMP OVERVIEW
  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

RADIATOR AND COOLANT FAN OVERVIEW

WARNINGRisk 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.
WARNINGRisk 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 .

Scheme 57

Scheme 57
Scheme 57
  1. Coolant Fan -V7- Removing and installing, refer to «COOLANT FANS»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__coolant-fans)
  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»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__radiator) 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 cooler
  12. Coolant Fan 2 -V177- Removing and installing, refer to «COOLANT FANS»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__coolant-fans)

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
After-Run Coolant Pump5
Connecting Piece10
Coolant Distribution Housing15
Coolant Fan, Nut10
Coolant Pipe 1
30
40
Coolant Pipe 25
Coolant Pipe, Nut 3
3
5
Coolant Pipe to Turbocharger5
Coolant Pump15
Fan Rib5
Radiator5
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 and 19- 3 For bolt tightening clarification, refer to AFTER-RUN COOLANT PUMP OVERVIEW and see items -1 and 14

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

WARNINGCover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Attach the V.A.G 1274 with the V.A.G 1274/8 to expansion tank.

Scheme 58

Scheme 58
Scheme 58

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 the V.A.G 1274 with V.A.G 1274/9 to expansion tank cap.

Scheme 59

Scheme 59
Scheme 59

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 V.A.G 1921

Removing

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Scheme 60

Scheme 60
Scheme 60

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Remove pipe -A- and hose -B- -arrows-.

Scheme 61

Scheme 61
Scheme 61

Remove the air duct -1 and 2- for charge air cooler.

Scheme 62

Scheme 62
Scheme 62

Loosen clamp -2-.

Scheme 63

Scheme 63
Scheme 63

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 64

Scheme 64
Scheme 64

Disconnect coolant hoses from coolant pipes -arrows-.

Scheme 65

Scheme 65
Scheme 65

Disconnect hose -A- and remove bolt -B-. Remove front coolant pipe.

Scheme 66

Scheme 66
Scheme 66

Disengage connector -A- from bracket, disconnect hose -B- and remove bolts -C-. Remove rear coolant pipe.

Scheme 67

Scheme 67
Scheme 67

Installing

Install in reverse order of removal. Note the following

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 [For transmission(s) 02E] Removal and Installation .

Disconnect coolant pipes. Refer to COOLANT PIPES .

Pull the coolant hose -2- off from coolant distribution housing, thereby pulling out retaining clip -1-.

Scheme 68

Scheme 68: COOLANT DISTRIBUTION HOUSING WITH MAP CONTROLLED ENGINE COOLING THERMOSTAT
Scheme 68: COOLANT DISTRIBUTION HOUSING WITH MAP CONTROLLED ENGINE COOLING THERMOSTAT

Remove bolts -arrows- and remove coolant distribution housing with map controlled engine cooling thermostat -F265- from engine.

Scheme 69

Scheme 69
Scheme 69

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «COOLING SYSTEM OVERVIEW»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__cooling-system-overview)

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

Clean sealing surface for O-ring.

Replace O-ring and coat it with coolant.

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

COOLANT PUMP

Special tools and workshop equipment required

  1. Drip Tray VAS 6208

Removing

WARNINGCover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove the front air intake connector on lock carrier -4-.

Remove engine cover.

Remove center noise insulation fasteners -1 to 4-.

Remove the right noise insulation -arrows-.

Scheme 70

Scheme 70
Scheme 70

Remove noise insulation frame -arrow-.

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

Remove toothed belt. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

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

Scheme 71

Scheme 71
Scheme 71

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»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__cooling-system-overview)

Clean and/or smooth O-ring sealing surface.

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

Insert coolant pump -2-.

  1. Installation position: Sealing plug in housing points downward

Tighten coolant pump bolts -1-.

Install toothed belt. Refer to TOOTHED BELT, WITHOUT 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 V.A.G 1921

Removing

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

WARNINGCover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.

Separate intake tubes -arrow- with the V.A.G 1921.

Scheme 72

Scheme 72
Scheme 72

Disconnect front air intakes on lock carrier -1- and remove them.

Remove the bolts -1- from above.

Scheme 73

Scheme 73
Scheme 73

Remove center noise insulation fasteners -1 to 4-.

Remove the air duct clamps -1 and 2- for charge air cooler.

Remove air duct -arrows-.

Scheme 74

Scheme 74
Scheme 74

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-.

Disconnect upper coolant hose from radiator -arrow-.

Scheme 75

Scheme 75
Scheme 75

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

Scheme 76

Scheme 76
Scheme 76

Lift radiator slightly and remove 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»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__radiator-and-coolant-fan-overview)

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

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 center noise insulation fasteners -1 to 4-.

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»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__radiator-and-coolant-fan-overview)

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

COOLANT FANS

Removing

Remove fan shroud. Refer to FAN SHROUD .

Disconnect the connector -1-.

Scheme 77

Scheme 77: COOLANT FANS
Scheme 77: COOLANT FANS

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»(/audi/tt/8j-2006-2010/remont/cooling-fan/#20l-cooling-system-engine-codes-bpy-coupe__radiator-and-coolant-fan-overview)

Install fan shroud. Refer to FAN SHROUD .

Scheme 78

Scheme 78: SPECIAL TOOLS
Scheme 78: SPECIAL TOOLS

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 79

Scheme 79
Scheme 79

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

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