2.0l - Cooling System - Engine Code(s): Ccta & Ceta (roadster) Audi TT 8J рестайлинг

COOLANT, DRAINING AND FILLING

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Drip Tray for VAS 6100 VAS 6208
3. Hose Clip Pliers V.A.G 1921
4. Cooling System Charge Unit VAS 6096
5. Refractometer T10007

Draining

Open the coolant reservoir cap.

Remove the noise insulation. Refer to Removal and Installation .

Remove the frame for the noise insulation. Refer to Removal and Installation .

Remove the air guide pipe -1 and 2-.

Scheme 347

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

Place the VAS 6208 under engine.

Remove the lower coolant hose -1- from the radiator and let the coolant drain.

Scheme 348

Note. Ignore -2-.

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

Scheme 349

FILLING

Note. The cooling system is filled year-round with a mixture of water and coolant additive. Mixture ratio COOLANT, DRAINING AND FILLING . Only use coolant according to Audi. 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 COOLANT, DRAINING AND FILLING prevents freezing and corrosion damage and calcium deposits. 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. 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. If the 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.

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)

Connect the lower coolant hose -1- to the radiator.

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

Fill coolant reservoir on VAS 6096 with 10 liters of premixed coolant with the proper mixture ratio COOLANT, DRAINING AND FILLING .

Scheme 350

Attach the V.A.G 1274/8 to the 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. Pressure: 6 to 10 bar pressure.

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

Scheme 351

1. The suction jet pump generates pressure in the coolant system; indicator on display instrument must move into green area.

Briefly open the 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 the display instrument must stay in the 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.

Check the coolant level.

Scheme 352

Fill coolant up to "max" marking.

Start engine and run at approximately 1500 RPM for a maximum of 2 minutes.

With the engine running, fill coolant up to overflow hole on coolant expansion tank.

Close the cap on the coolant reservoir.

Start the engine and let it run at approximately 3000 RPM until the coolant fan starts running.

Check coolant level.

1. With warm engine, coolant level must be at "max" marking, with cold engine, between "min" and "max" marking.

If necessary, fill with coolant again.

Shut off engine.

Assemble in reverse order of disassembly.

Note. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps of the same type as those equipped by the factory. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

COOLANT HOSE CONNECTION DIAGRAM

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 type. 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.

Vehicles with 6-Speed Manual Transmission 02S

Scheme 353

1. Radiator Change coolant after replacing
2. After-Run Coolant Pump -V51
3. Coolant Pump
4. Coolant Thermostat
5. Engine Oil Cooler
6. Cylinder Head and Cylinder Block
7. Turbocharger
8. Coolant Reservoir With sealing cap Pressure relief valve in cap, checking, refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__cooling-system-checking-for-leaks)
9. Heat Exchanger for Heater Unit
10. Coolant Connection

Vehicles with S-Tronic Transmission 02E

Scheme 354

1. Radiator
2. After-Run Coolant Pump -V51
3. Coolant Pump
4. Coolant Thermostat
5. Engine Oil Cooler
6. Cylinder Head and Cylinder Block
7. Turbocharger
8. Coolant Reservoir With sealing cap Pressure relief valve in cap, checking, refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__cooling-system-checking-for-leaks)
9. Heat Exchanger for Heater Unit
10. Transmission Oil Cooler
11. Coolant Connection
12. Thermostat for the Transmission Oil Cooler

Scheme 355

1. Bracket
2. Bolt 5 Nm
3. Coolant Hose
4. Coolant Hose
5. After-Run Coolant Pump -V51
6. Bracket
7. Bolt 4 Nm

Scheme 356

1. Front Coolant Pipes Removing and installing, refer to «FRONT COOLANT PIPES»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__front-coolant-pipes)
2. Coolant Hose From turbocharger
3. Coolant Hose To the coolant reservoir
4. Bolt 5 Nm
5. O-ring Replace
6. Coolant Hose To heat exchanger for heater unit
7. Small Coolant Pipe Removing and installing, refer to «SMALL COOLANT PIPE»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__small-coolant-pipe)
8. Bolts 9 Nm
9. Coolant Hose
10. Bolt 5 Nm
11. Coolant Hose From after-run coolant pump -V51
12. Coolant Hose To after-run coolant pump -V51

Scheme 357

1. O-ring Replace
2. Connection
3. Retaining Clip Make sure it is secure
4. Engine Coolant Temperature (ECT) Sensor -G62- Removing and installing, refer to «Engine Coolant Temperature (ECT) Sensor -G62»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__engine-coolant-temperature-ect-sensor-g62)
5. O-ring Replace
6. Bolt Tightening sequence (Scheme 358)
7. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__coolant-pump) With a new coolant pump, remove the protective cap
8. Gasket Replace
9. Centering Pins Quantity: 2
10. Toothed Belt For coolant pump Removing and installing, refer to «COOLANT PUMP TOOTHED BELT»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__coolant-pump-toothed-belt)
11. Toothed Belt Guard
12. Bolt 9 Nm
13. Bolt 10 Nm plus an additional 90° turn Replace Left thread
14. Drive Gear for Toothed Belt Pay attention to the installed position
15. Shaft Seal Removing and installing, refer to «COOLANT PUMP DRIVE SHAFT SEAL»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__coolant-pump-drive-shaft-seal)
16. Balance Shaft
17. Coolant Thermostat Removing and installing, refer to «COOLANT THERMOSTAT»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__coolant-thermostat)
18. Centering Pin
19. Connecting Piece
20. Bolt 9 Nm
21. O-ring Replace

Scheme 358

Tighten the bolt in the following sequence: -1 to 8-.

1. 9 Nm

RADIATOR, FAN SHROUD AND COOLANT FAN OVERVIEW

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 type. 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 359

1. Coolant Fan -V7- Removing and installing, refer to «Coolant Fan -V7- AND Coolant Fan 2 -V177»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__coolant-fan-v7-and-coolant-fan)
2. Nut 10 Nm
3. Fan Shroud
4. Lower Coolant Hose To connection for coolant regulator
5. Retaining Clip
6. Coolant Temperature Sensor -G62- Removing and installing, refer to «Engine Coolant Temperature (ECT) Sensor -G62»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__engine-coolant-temperature-ect-sensor-g62)
7. O-ring Replace if damaged
8. Upper Coolant Hose From coolant pump
9. O-ring Replace if damaged
10. Bolt 5 Nm To charge air cooler
11. Radiator Removing and installing, refer to «RADIATOR»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__radiator) After replacing replace entire amount of coolant
12. Nut 10 Nm
13. Bolt 5 Nm To cooler
14. Coolant Fan 2 -V177- Removing and installing, refer to «Coolant Fan -V7- AND Coolant Fan 2 -V177»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__coolant-fan-v7-and-coolant-fan)

FASTENER TIGHTENING SPECIFICATIONS

Coolant Pump Tightening Sequence

Tighten the bolt in the following sequence: -1 to 8-.

1. 9 Nm

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.

Scheme 360

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

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

If pressure falls, search for leaks and correct the problem.

Pressure Relief Valve in Cap, Checking

Scheme 361

Attach V.A.G 1274 B with V.A.G 1274/9 to the 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.

AFTER-RUN COOLANT PUMP -V51

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094
2. Hose Clip Pliers V.A.G 1921
3. Drip Tray for VAS 6100 VAS 6208

Removing

Open the coolant reservoir cap.

Remove the noise insulation. Refer to Removal and Installation .

Remove the frame for the noise insulation. Refer to Removal and Installation .

Disconnect the electrical connector -1- for the after-run coolant pump.

Scheme 362

Place the VAS 6208 under the engine.

Disconnect the coolant hoses -arrows- together with the 3094.

Remove coolant hoses from after-run coolant pump.

Remove the bolt -2- and the after-run coolant pump.

Installing

1. For the correct tightening specifications, refer to «After-Run Coolant Pump -V51- OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster) .

Installation is carried out in reverse order while noting the following

Fill coolant system. Refer to COOLANT, DRAINING AND FILLING .

Coolant Fan -V7- AND Coolant Fan 2 -V177

Removing

Scheme 363

Remove fan shroud. Refer to FAN SHROUD .

Disconnect the connector -1-.

Free up electrical wires.

Remove nuts -arrows- and remove coolant fan.

Installing

1. For the correct tightening specifications, refer to «RADIATOR, FAN SHROUD AND COOLANT FAN OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__radiator-fan-shroud-and-coolant-fan) .

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

Install fan shroud. Refer to FAN SHROUD .

COOLANT PUMP

Removing

Remove small coolant pipe. Refer to SMALL COOLANT PIPE .

Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Disconnect electrical connector -1- on throttle valve control module -J338-.

Scheme 364

Remove bolts -arrows- and remove throttle valve control module.

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

Scheme 365

Note. Ignore -2 and arrows-.

Remove the bolts -1 to 5-.

Remove the coolant pump from the centering pin and remove the engine oil cooler.

Note. Ignore -arrow-.

Installing

1. For the correct tightening specifications (Scheme 358)

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

Note. Replace the seals and the O-rings. -- Coat the O-rings -4- with coolant.

Scheme 366

Make sure both centering pins are installed in the cylinder block.

Install the connection piece -2- into the engine oil cooler -1-.

Push the coolant pump -3- onto the connection piece and onto the centering pins in the cylinder block.

Tighten bolts -1 to 5-.

Note. If a new coolant pump was installed, then the protective cap -arrow- must be removed.

Install the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

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

Install the small coolant pipe. Refer to SMALL COOLANT PIPE .

Install the after-run coolant pump -V51- After-Run Coolant Pump -V51 .

Fill coolant system. Refer to COOLANT, DRAINING AND FILLING .

COOLANT PUMP DRIVE SHAFT SEAL

Special tools and workshop equipment required

1. Thrust Piece T10353

Procedure

Scheme 367

Remove small coolant pipe. Refer to SMALL COOLANT PIPE .

Remove the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Firmly press a screwdriver -1- on the seal surface -2- -arrow B-.

Pry out the seal -arrow A-.

Clean the running and sealing surface.

Coat the sealing surface of the balance shaft -2- with transmission oil.

Scheme 368

Push the seal -1- onto the balance shaft.

1. "Luftseite" or ("Outside") -arrow- must be readable from the outside.

Mount the T10353 on the shaft seal -1- and then tighten it all the way into the cylinder block with the screw -2-. Be careful not to tilt the shaft seal when doing this.

Scheme 369

Install the coolant pump toothed belt. Refer to COOLANT PUMP TOOTHED BELT .

Install after-run coolant pump -V51-. Refer to After-Run Coolant Pump -V51 .

Install the small coolant pipe. Refer to SMALL COOLANT PIPE .

Fill the coolant system. Refer to COOLANT, DRAINING AND FILLING .

COOLANT PUMP TOOTHED BELT

Special tools and workshop equipment required

1. Insert Tool 12 mm T10360
2. Torque Wrench 5-50 Nm V.A.G 1331

Removing

Scheme 370

Remove small coolant pipe. Refer to SMALL COOLANT PIPE .

Free up the coolant hose -2- and electrical wiring harness -1-.

Remove the bolt -arrow- and remove bracket.

Remove the bolt -2- on the bracket for the after-run coolant pump -V51-.

Note. Ignore -1 and arrows-.

Remove the coolant hoses -1 and 2- and lay them aside.

Scheme 371

Remove the bolts -arrows- and remove the toothed belt guard.

Scheme 372

Remove the bolt on the coolant pump drive gear -1- using a V.A.G 1331 and T10360 while counterholding the vibration damper.

Scheme 373

Remove the drive gear -1- and toothed belt -2-.

Installing

1. For the correct tightening specifications, refer to «COOLANT PUMP AND THERMOSTAT OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster) .

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

Note. Replace the drive gear bolt. Replace the seals and the O-rings. Note the toothed belt sprocket installation location COOLANT PUMP AND THERMOSTAT OVERVIEW .

Install the after-run coolant pump. Refer to After-Run Coolant Pump -V51 .

Install the small coolant pipe. Refer to SMALL COOLANT PIPE .

Fill the coolant system. Refer to COOLANT, DRAINING AND FILLING .

COOLANT THERMOSTAT

Removing

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove the bolt -1- from below.

Scheme 374

Note. Ignore items -2, 3 and 4 and the arrow-.

Remove the bolts -arrows- and air guide.

Scheme 375

Remove both the lower air guide and the air guide hose.

Disconnect the electrical connectors -arrow- and free up the electrical wire.

Loosen the hose clamp -2- from above.

Remove the bolt -4- and the air guide pipe.

Note. Ignore -1 and 3-.

Free up the coolant hose -2- and electrical wiring harness -1-.

Remove the bolt -arrow- and remove the bracket.

Remove the bolt -2- on the bracket for the after-run coolant pump -V51-.

Note. The after-run coolant pump stays in the installation position. Ignore -1 and arrows-.

Remove the coolant hoses -1 and 2- and lay them aside.

Remove the bolts -1 through 9- and remove the oil separator.

Scheme 376

Loosen the nut -2-, remove the bolt -1- and move the support for the intake manifold to the right.

Scheme 377

Remove bolts -arrows- and remove connecting pieces.

Scheme 378

Remove the coolant thermostat.

Installing

1. For the correct tightening specifications, refer to «COOLANT PUMP AND THERMOSTAT OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster) .

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

Note. Replace the seals and the O-rings. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps of the same type as those equipped by the factory. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

Clean O-ring sealing surface.

Coat the O-ring with coolant.

Install the thermostat -4- into the housing -5- for the coolant pump and move it slightly forward -arrow-.

Scheme 379

Carefully mount the connector -3- ; while doing this, insert the centering pin -2- into the guide -1-.

Install the oil separator. Refer to OIL SEPARATOR .

Install the intake manifold support. Refer to Removal and Installation .

Install the after-run coolant pump. Refer to After-Run Coolant Pump -V51 .

Air guides, installing with connector. Refer to AIR GUIDE PIPES AND HOSES WITH CONNECTOR COUPLING

Fill the coolant system. Refer to COOLANT, DRAINING AND FILLING .

ENGINE COOLANT TEMPERATURE (ECT) SENSOR -G62

Removing

1. Engine cold.

Remove the bolts -arrows- and air guide.

Remove both the lower air guide and the air guide hose.

Remove the air guide hose -2 and 3-.

Note. Ignore items -1, 2 and arrows-.

Disconnect electrical connector -1- on throttle valve control module -J338-.

Remove bolts -arrows- and remove throttle valve control module.

Remove the intake manifold support; to do this, remove the nut -2- and bolt -1-.

Disconnect the connector -1- from the ECT sensor.

Note. Use a cloth to catch any leaking coolant.

Remove the clamp, to do this, press the latches -arrow-.

Remove the ECT sensor -2-.

Installing

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

Note. Replace the O-ring. To prevent coolant loss, immediately insert new ECT sensor in connecting pieces.

Install the intake manifold support. Refer to Removal and Installation .

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

Check the coolant level. Refer to COOLANT, DRAINING AND FILLING .

FAN SHROUD

Removing

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

Remove the bolts -arrows- and air guide.

Remove both the lower air guide and the air guide hose.

Remove the noise insulation. Refer to Removal and Installation .

Remove the frame for the noise insulation. Refer to Removal and Installation .

Remove the air guide hose -1 and 2-.

Remove the bolt -1- from below.

Note. Ignore items -2, 3 and 4 and the arrow-.

Disconnect the connector -2-.

Scheme 380

Remove the bolts -3-.

Disconnect the electrical connectors -arrow- and free up the electrical wire.

Loosen the hose clamp -2- from above.

Remove the bolt -4- and the air guide pipe.

Note. Ignore -1 and 3-.

Remove the bolts -1- from above and the fan shroud.

Installing

1. For the correct tightening specifications, refer to «RADIATOR, FAN SHROUD AND COOLANT FAN OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__radiator-fan-shroud-and-coolant-fan) .

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

Air guides, installing with connector. Refer to AIR GUIDE PIPES AND HOSES WITH CONNECTOR COUPLING

Note. 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.

FRONT COOLANT PIPES

Special tools and workshop equipment required

1. Hose Clip Pliers V.A.G 1921
2. Drip Tray for VAS 6100 VAS 6208

Removing

Open the coolant reservoir cap.

Remove the bolts -arrows- and air guide.

Remove both the lower air guide and the air guide hose.

Loosen the hose clamp -2-.

Remove the bolt -4-.

Disconnect the electrical connectors -arrow- and free up the electrical wire.

Note. Ignore -1 and 3-.

Remove the noise insulation. Refer to Removal and Installation .

Remove the frame for the noise insulation. Refer to Removal and Installation .

Remove the air guide pipe -1 and 2-.

Remove the bolt -1- and remove the air guide pipe downward.

Note. Ignore items -2, 3 and 4 and the arrow-.

Place the VAS 6208 under the engine.

Remove the coolant hoses from the after-run coolant pump -V51- -arrows-.

Note. Ignore -1 and 2-.

Remove the bolts -1 and 2- and remove the front coolant pipes from the coolant hoses -arrows-.

Scheme 381

Installing

1. For the correct tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster) .

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

Note. Always replace gaskets and seals. 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.

Air guides, installing with connector. Refer to AIR GUIDE PIPES AND HOSES WITH CONNECTOR COUPLING

Fill the coolant system. Refer to COOLANT, DRAINING AND FILLING .

RADIATOR

Special tools and workshop equipment required

1. 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 .

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove fan shroud. Refer to FAN SHROUD .

Remove air guide hose -arrows-.

Scheme 382

Remove the upper coolant hose -arrow- from the radiator.

Scheme 383

Remove the bolts -1 and 2- and remove the radiator upward.

Scheme 384

Installing

1. For the correct tightening specifications, refer to «RADIATOR, FAN SHROUD AND COOLANT FAN OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster__radiator-fan-shroud-and-coolant-fan) .

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

Air guides, installing with connector. Refer to AIR GUIDE PIPES AND HOSES WITH CONNECTOR COUPLING

Install the fan shroud. Refer to FAN SHROUD .

Fill the coolant system. Refer to COOLANT, DRAINING AND FILLING .

SMALL COOLANT PIPE

Special tools and workshop equipment required

1. Hose Clip Pliers V.A.G 1921

Removing

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

Remove the bolts -arrows- and air guide.

Remove both the lower air guide and the air guide hose.

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Scheme 385

Remove the air guide hose -2-.

Remove the bolt -4- and the air filter housing.

Note. Ignore -3-.

Loosen the hose clamp -2-.

Remove the bolt -4-.

Disconnect electrical connector -arrow-.

Remove the bolt -1- and remove the air guide pipe downward.

Note. Ignore -3-.

Remove the bolts -arrows- and remove the electrical connectors -1 through 3- from the bracket.

Scheme 386

Free up the electrical wiring harness on the small coolant pipe -arrow-.

Scheme 387

Remove bolts -2 and 3-.

Disconnect the small coolant pipe from the coolant pump and from the coolant hoses -1 and 4-.

Installing

1. For the correct tightening specifications, refer to «COOLANT PIPES OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#20l-cooling-system-engine-codes-ccta-ceta-roadster) .

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

Note. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps of the same type as those equipped by the factory. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

Air guides, installing with connector. Refer to AIR GUIDE PIPES AND HOSES WITH CONNECTOR COUPLING

Fill the coolant system. Refer to COOLANT, DRAINING AND FILLING .

Scheme 388

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Drip Tray for VAS 6100 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 389

Scheme 390

Scheme 391

Scheme 392

Scheme 393

Scheme 394

1. Hose Clamps Up to 25 mm Dia. 3094
2. Thrust Piece T10353
3. Insert Tool 12 mm T10360
4. Cooling System Tester V.A.G 1274 B
5. Adapter V.A.G 1274/9
6. Hose Clip Pliers V.A.G 1921
7. Not illustrated
8. Torque Wrench 5-50 Nm V.A.G 1331

See also:
• Removal and Installation
• Removal and Installation
• Removal and Installation
• OIL SEPARATOR
• AIR GUIDE PIPES AND HOSES WITH CONNECTOR COUPLING
• COOLERS, CONDENSERS AND CHARGE AIR COOLERS
• COOLANT, DRAINING AND FILLING
• COOLING SYSTEM, CHECKING FOR LEAKS
• FRONT COOLANT PIPES
• SMALL COOLANT PIPE
• Engine Coolant Temperature (ECT) Sensor -G62
• COOLANT PUMP
• COOLANT PUMP TOOTHED BELT
• COOLANT PUMP DRIVE SHAFT SEAL
• COOLANT THERMOSTAT
• Coolant Fan -V7- AND Coolant Fan 2 -V177
• RADIATOR
• After-Run Coolant Pump -V51- OVERVIEW
• FAN SHROUD
• RADIATOR, FAN SHROUD AND COOLANT FAN OVERVIEW
• After-Run Coolant Pump -V51