2.5l - Cooling System - Engine Code(s): Cepb (coupe) Audi TT 8J рестайлинг

COOLANT, DRAINING AND FILLING

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Cooling System Charge Unit VAS 6096 with Replacement Reservoir VAS 6096/1
3. Drip Tray for VAS 6100 VAS 6208
4. Hose Clip Pliers VAS 6362
5. Refractometer T10007

DRAINING

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

Scheme 1

Open the coolant reservoir cap.

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

Scheme 2

Place VAS 6208 under the engine.

Scheme 3

Loosen the hose clamp -arrow-, remove the coolant hose and drain the coolant.

Loosen the hose clamp -arrow-, remove the coolant hose and drain the coolant.

Scheme 4

FILLING

Note. The cooling system is filled year-round with a mixture of water and coolant additive. Mixture ratio RADIATOR . 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 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 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. 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 determine the level of freeze protection in the coolant system. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

COOLANT MIXTURE RATIO

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

Procedure

Connect the coolant hose -arrow-.

Connect the coolant hose -arrow-.

Fill coolant reservoir on VAS 6096 with 10 liters of premixed coolant with the proper mixture ratio, refer to COOLANT MIXTURE RATIO .

Scheme 5

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

Install the VAS 6096 on V.A.G 1274/8.

Place the 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 6

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 7

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 the cap on the coolant reservoir until it latches.

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. Secure all hose connections with hose clamps of the same type as those equipped by the factory. Arrows on coolant pipes and ends of coolant hoses must align when installing.

Vehicles with a Manual Transmission

Note. Blue = large coolant circuit. Red = small coolant circuit with heating circuit. Orange = coolant circuit for turbocharger. The arrows show the coolant flow direction.

Scheme 8

1. Radiator Change coolant after replacing
2. Coolant Auxiliary Cooler Change coolant after replacing
3. Non-Return Valve The arrow points in the flow direction
4. Coolant Thermostat with Housing
5. Coolant Pump
6. Cylinder Head and Cylinder Block Change coolant after replacing
7. Coolant Reservoir With cover and pressure relief valve Pressure relief valve, checking «PRESSURE RELIEF VALVE IN CAP, CHECKING»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe)
8. Heat Exchanger for Heater Unit Change coolant after replacing
9. Bleeder Screw
10. Restrictor
11. Turbocharger
12. Engine Coolant Temperature Sensor -G62
13. Engine Oil Cooler Change coolant after replacing
14. After-Run Coolant Pump -V51
15. Coolant Circuit Solenoid Valve -N492

Scheme 9

1. Right Coolant Pipe Removing and installing, refer to «RIGHT COOLANT PIPE»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__right-coolant-pipe)
2. Bolt 9 Nm
3. O-ring Replace
4. Nut 9 Nm
5. Retaining Clip
6. Coolant Temperature Sensor -G62- Removing and installing, refer to «Engine Coolant Temperature Sensor -G62»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__engine-coolant-temperature-sensor-g62)
7. O-ring Replace
8. Coolant Connection
9. Nut 9 Nm
10. Left Coolant Pipe Removing and installing, refer to «LEFT COOLANT PIPE»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__left-coolant-pipe)
11. Bolt 9 Nm
12. Front Coolant Pipes Removing and installing, refer to «FRONT COOLANT PIPES»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__front-coolant-pipes)
13. Bolt 9 Nm
14. Bolt 9 Nm
15. Clamp
16. Bolt 9 Nm
17. O-ring Replace

COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW

Scheme 10

1. Seal Replace
2. Bolt 9 Nm
3. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-pump)
4. After-Run Coolant Pump -V51- Removing and installing, refer to «After-Run Coolant Pump -V51»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__after-run-coolant-pump-v51)
5. Bolt 9 Nm
6. Coolant Circuit Solenoid Valve -N492- Removing and installing, refer to «Cooling Circuit Solenoid Valve -N492»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__cooling-circuit-solenoid-valve-n492)
7. Bolt 9 Nm
8. Coolant Distribution Housing Removing and installing, refer to «COOLANT DISTRIBUTION HOUSING»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-distribution-housing)
9. O-ring Replace
10. Bolt 6 Nm
11. Front Coolant Pipes
12. Bolt 9 Nm
13. O-ring Replace
14. Coolant Thermostat with Housing Removing and installing, refer to «COOLANT THERMOSTAT WITH HOUSING»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-thermostat-with-housing)
15. Bolt 9 Nm

RADIATOR AND COOLANT FAN OVERVIEW

Radiator, Coolant Fan

Scheme 11

1. Coolant Fan -V7- Removing and installing, refer to «Coolant Fan -V7- /Coolant Fan 2 -V177»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-fan-v7-coolant-fan-2)
2. Nut 10 Nm
3. Fan Shroud Removing and installing, refer to «FAN SHROUD»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__fan-shroud)
4. Upper Coolant Hose Connect to the radiator (Scheme 12)
5. Coolant Hose
6. O-ring Replace
7. Radiator Removing and installing, refer to «RADIATOR»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__radiator) After replacing, replace entire amount of coolant
8. Bolt 5 Nm
9. Bracket
10. Mount
11. O-ring Replace
12. Lower Coolant Hose Connect to the radiator (Scheme 12)
13. Nut 10 Nm
14. Bolt 5 Nm
15. Coolant Fan 2 -V177- Removing and installing, refer to «Coolant Fan -V7- /Coolant Fan 2 -V177»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-fan-v7-coolant-fan-2)

Scheme 12

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

Coat the new O-ring with coolant and install 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.

Left Auxiliary Cooler

Scheme 13

1. Air Guide
2. Grommet
3. Bolt 8 Nm
4. Upper Bracket
5. Grommet
6. Bolt 8 Nm
7. Coolant Hoses
8. Left Auxiliary Cooler For coolant circuit for the transmission Removing and installing, refer to «LEFT AUXILIARY COOLER»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__left-auxiliary-cooler)
9. Grommet
10. Lower Bracket
11. Washer
12. Nut 8 Nm

Scheme 14

1. Bolt 6.5 Nm
2. Air Guide
3. Right Auxiliary Cooler For coolant Removing and installing, refer to «RIGHT AUXILIARY COOLER»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe)
4. Coolant Hoses
5. Upper Bracket
6. Grommets
7. Coolant Hose
8. Grommet
9. Bushing
10. Bolt 6.5 Nm
11. Lower Bracket
12. Bolt 8 Nm
13. Grommet
14. Bolt 6 Nm

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 15

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

If pressure falls, search for leaks and correct problem.

Scheme 16

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.

AFTER-RUN COOLANT PUMP -V51

Special tools and workshop equipment required

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

Removing

Scheme 17

Remove the bolts -arrows- and front air guide.

Note. Use a cloth to catch any leaking coolant.

Disconnect the connector -2-.

Disconnect and remove the coolant hoses -3- using the 3094.

Remove the bolt -1- and the after-run coolant pump.

Installing

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-pump-and-coolant-thermostat-with) .

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Install the front air guide. Refer to Description and Operation .

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

COOLANT DISTRIBUTION HOUSING

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6362

Removing

Scheme 18

Remove the upper intake manifold. Refer to Removal and Installation .

Remove the thermostat and housing. Refer to COOLANT THERMOSTAT WITH HOUSING .

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

Scheme 19

Remove the bolts -arrows- and remove the coolant distribution housing -2- from the cylinder block towards the left.

Installing

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

1. For the correct tightening specifications, refer to «COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-pump-and-coolant-thermostat-with) .

Note. Replace the O-rings. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

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

Coat the O-ring with coolant and slide it onto the coolant distribution housing.

Insert coolant distribution housing in hole at cylinder block.

Install the thermostat and its housing. Refer to COOLANT THERMOSTAT WITH HOUSING .

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

COOLANT FAN -V7- /COOLANT FAN 2 -V177

Removing

Scheme 20

Remove fan shroud. Refer to FAN SHROUD .

Disconnect the connector -1-.

Free up the wires.

Remove nuts -arrows- and remove coolant fan.

Installing

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__radiator-and-coolant-fan-overview) .

Install fan shroud. Refer to FAN SHROUD .

COOLANT PUMP

Removing

Scheme 21

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

Remove the bolts -2 and 3-.

Note. Ignore -1-.

Remove the bolts -arrows- and the cross brace -1-.

Scheme 22

Note. Ignore -2 and 3-.

Remove the engine bracket. Refer to ENGINE MOUNT .

Pivot the tensioner clockwise -arrow- to release the tension on the ribbed belt.

Scheme 23

Remove the ribbed belt from the generator and release the tension on the tensioning element.

Lift the engine with the left spindle to the dimension -a

Scheme 24

1. Dimension: -a- 55 mm.

Remove the bolts -arrows- through the holes in the ribbed belt pulley and remove the coolant pump.

Scheme 25

Installing

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-pump-and-coolant-thermostat-with) .

Clean and smooth the sealing surface for the integrated silicon seal on the coolant pump.

Install the engine mount. Refer to ENGINE MOUNT .

Install the generator ribbed belt and the coolant pump. Refer to GENERATOR RIBBED BELT AND COOLANT PUMP .

Install cross brace. Refer to MUFFLER OVERVIEW .

Install the pendulum support. Refer to Description and Operation or to Description and Operation .

Fill the engine with coolant. Refer to FILLING .

COOLANT THERMOSTAT WITH HOUSING

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6362

Removing

Scheme 26

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

Remove the oil dipstick -2-.

Remove the bolts -arrows-, then remove oil dipstick tube -1- upward.

Remove the coolant hose from the T-connection and loosen the hose clamp -arrow-.

Scheme 27

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

Scheme 28

Remove the bolt -arrow- on the retaining clamp.

Scheme 29

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

Scheme 30

Remove the bolts and nut -arrows- and then remove the front coolant pipe from the thermostat housing.

Note. Ignore -2, 3 and 4-.

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

Scheme 31

Installing

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

1. Tightening specification, refer to «COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-pump-and-coolant-thermostat-with) .

Note. Replace the O-ring. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Clean and smooth the O-ring sealing surface.

Coat the new O-ring with coolant.

Install the front coolant pipes. Refer to FRONT COOLANT PIPES .

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

Tighten the oil dipstick guide tube. (Scheme 32)

Fill the engine with coolant. Refer to FILLING .

COOLING CIRCUIT SOLENOID VALVE -N492

Special tools and workshop equipment required

Scheme 32

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

Removing

Remove the bolts -arrows- and air guide.

Note. Use a cloth to catch any leaking coolant.

Disconnect the connector -1-.

Disconnect and remove the coolant hoses -2- using the 3094.

Remove the bolts -arrows- and remove the cooling circuit solenoid valve.

Installing

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__coolant-pump-and-coolant-thermostat-with) .

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Install the front air guide. Refer to Description and Operation .

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

ENGINE COOLANT TEMPERATURE SENSOR -G62

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 .

Disconnect the connector -1-.

Scheme 33

Note. Use a cloth to catch any leaking coolant.

Remove the clip -2- and then remove the Engine Coolant Temperature (ECT) sensor.

Installing

Install in reverse order, paying attention to the following

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

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

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

FAN SHROUD

Removing

Remove the bolts -arrows- and front air guide.

Remove the bolts -1-, and set the charge air pressure sensor -G31- / intake air temperature sensor 2 -G299- with attached connector -3- aside.

Scheme 34

Loosen the hose clamp -2-.

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

Vehicles with a Manual Transmission

Scheme 35

Remove the bolt -1-.

Remove the air guide pipe; to do this, loosen the hose clamp -2-.

Scheme 36

Disconnect the radiator fan connector -2-.

Remove the bolts -3-.

Unclip -arrows- the coolant line -1- from the lock carrier and set it towards the rear.

Scheme 37

Remove the bolts -1- and remove the fan shroud upward.

Installing

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__radiator-and-coolant-fan-overview) .

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

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

Install the noise insulation. Refer to Removal and Installation .

Install the charge air pressure sensor / intake air temperature sensor 2. Refer to Charge Air Pressure Sensor -G31- / AND Intake Air Temperature (IAT) Sensor 2 -G299 .

Install the front air guide. Refer to Description and Operation .

FRONT COOLANT PIPES

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6362

Removing

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

Remove the upper intake manifold. Refer to Removal and Installation .

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

Remove the bolt -arrow- on the retaining clamp.

Remove electrical harness connectors -1 and 2- from the bracket.

Scheme 38

Remove the nut and bolt -arrows- and then remove the mount.

Vehicles with a Manual Transmission

Remove coolant hoses by loosening the hose clamps -1 to 4-.

Remove the bolts and nut -arrows- and then remove the front coolant pipe from the thermostat housing.

Installing

Install in reverse order, paying attention to the following

Tightening specifications

1. «COOLANT PIPES OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe) .
2. «TIMING CHAIN COVERS OVERVIEW»(/audi/tt/8j-2010-2014/remont/mechanical/#25l-cylinder-head-valvetrain-engine-codes-cepb-coupe) .

Note. Replace the O-ring. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Install the exhaust gas temperature sensor 1 -G235-. Refer to Exhaust Gas Temperature (EGT) Sensor 1 -G235 .

Install the intake manifold upper section and air filter housing. Refer to Removal and Installation .

Fill the engine with coolant. Refer to RADIATOR .

LEFT AUXILIARY COOLER

Special tools and workshop equipment required

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

Removing

Scheme 39

Remove the left front underside of wheel housing liner. Refer to Removal and Installation .

Remove the bumper cover. Refer to Removal and Installation .

Unclip the air guide -1- towards the front.

Scheme 40

Remove the bolts -1- and nut -2-.

Scheme 41

Note. Use a cloth to catch any leaking coolant.

Remove the auxiliary cooler and lower it slightly.

Disconnect and remove the coolant hoses -arrows- using the 3094.

Installing

Install in reverse order, paying attention to the following

1. For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__radiator-and-coolant-fan-overview) .

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Install the bumper cover. Refer to Removal and Installation .

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

Fill the engine with coolant. Refer to COOLANT, DRAINING AND FILLING .

LEFT COOLANT PIPE

Special tools and workshop equipment required

1. Hose clip pliers VAS 6362

Removing

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

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

Vehicles with a Manual Transmission

Scheme 42

Pull the safety mechanism all the way to the front -arrow 1- and then lock it to the left -arrow 2-.

Push the shift relay lever forward -arrow 3- and remove the selector cable from the retainer.

Remove the lock washer -1- for the shift cable from the transmission selector lever -2- and remove the shift cable from the pin -arrow-.

Scheme 43

Remove the bolts -arrows-, then remove the cable bracket from the transmission and tie it up to the left.

Scheme 44

Disconnect the vacuum hose -2-.

Scheme 45

Free up the vacuum hose -1- -arrow- and remove it from the brake booster vacuum pump.

Remove the bolts and nuts -arrows-.

Scheme 46

Remove the left coolant pipe in order to loosen the hose clamp -2-.

Note. Ignore -1-.

Installing

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe) .

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Selector mechanism, installing and adjusting. Refer to Removal and Installation or to Removal and Installation .

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

Fill the engine with coolant. Refer to COOLANT, DRAINING AND FILLING .

RADIATOR

Special tools and workshop equipment required

1. Drip Tray for VAS 6100 VAS 6208

Removing

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

Open the coolant reservoir cap.

Remove the charge air cooler. Refer to CHARGE AIR COOLER .

Remove the noise insulation frame -arrow- with the rear noise insulation. Refer to Removal and Installation .

Scheme 47

Remove the fan shroud. Refer to FAN SHROUD .

Place the VAS 6208 under engine.

Scheme 48

Open the clamp, drain the coolant and then remove the lower coolant hose -arrow- from the radiator.

Remove nuts -1- and push the coolant pipe toward the rear.

Scheme 49

Note. Ignore -2-.

Disconnect the coolant hose from the radiator by raising the retaining clip -arrow-.

Scheme 50

Remove the bolts -arrows-.

Scheme 51

Tip radiator back slightly at upper edge.

Disengage radiator from lower mounting points by raising radiator.

Slide radiator in direction of engine.

To prevent radiator from sinking down, support it from below.

Scheme 52

Remove the bolts -arrows-.

Remove condenser from radiator.

Place condenser forward in lock carrier and secure against falling down with cable ties.

Remove radiator downward.

Installing

Install in reverse order, paying attention to the following

1. For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__radiator-and-coolant-fan-overview) .

Install condenser. Refer to Removal and Installation .

Install fan shroud. Refer to FAN SHROUD .

Connect the coolant hose to the connector on the radiator. (Scheme 12)

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

Install the charge air cooler. Refer to CHARGE AIR COOLER .

Fill the engine with coolant. Refer to COOLANT, DRAINING AND FILLING .

RIGHT AUXILIARY COOLER

Special tools and workshop equipment required

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

Removing

Scheme 53

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

Remove the bumper cover. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the air guide -1- downward.

Scheme 54

Remove the bolts -arrows- and remove the auxiliary cooler bracket -1-.

Scheme 55

Note. Use a cloth to catch any leaking coolant.

Lower the auxiliary cooler -1- slightly.

Disconnect and remove the coolant hoses -arrows- using the 3094.

Installing

Install in reverse order, paying attention to the following

1. For the correct tightening specifications, refer to «RADIATOR AND COOLANT FAN OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe__radiator-and-coolant-fan-overview) .

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Install the bumper cover. Refer to Removal and Installation .

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

Fill the engine with coolant. Refer to COOLANT, DRAINING AND FILLING .

RIGHT COOLANT PIPE

Special tools and workshop equipment required

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

Removing

Scheme 56

Release the EVAP canister -arrow B-, remove upward -arrow A- and lay it to the side along with the connected hose -1-.

Note. Ignore -2-.

Note. Use a cloth to catch any leaking coolant.

Disconnect the coolant hoses -1 and 3- and remove them using the 3094.

Remove the bolt -2- and remove the right coolant pipe.

Installing

Install in reverse order, paying attention to the following

1. Tightening specification, refer to «COOLANT PIPES OVERVIEW»(/audi/tt/8j-2010-2014/remont/cooling-fan/#25l-cooling-system-engine-codes-cepb-coupe) .

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Check the coolant level. Refer to FILLING .

Scheme 57

Special tools and workshop equipment required

1. Adapter V.A.G 1274/8
2. Cooling System Charge Unit VAS 6096 with Replacement Reservoir VAS 6096/1
3. Drip Tray for VAS 6100 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

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

See also:
• Removal and Installation
• Description and Operation
• ENGINE MOUNT
• GENERATOR RIBBED BELT AND COOLANT PUMP
• MUFFLER OVERVIEW
• Description and Operation
• CHARGE AIR COOLER OVERVIEW
• Charge Air Pressure Sensor -G31- / AND Intake Air Temperature (IAT) Sensor 2 -G299
• TIMING CHAIN COVERS OVERVIEW
• Exhaust Gas Temperature (EGT) Sensor 1 -G235
• Removal and Installation
• COOLERS, CONDENSERS AND CHARGE AIR COOLERS
• CHARGE AIR COOLER
• Removal and Installation
• Removal and Installation
• RADIATOR
• FILLING
• COOLANT MIXTURE RATIO
• PRESSURE RELIEF VALVE IN CAP, CHECKING
• RIGHT COOLANT PIPE
• Engine Coolant Temperature Sensor -G62
• LEFT COOLANT PIPE
• FRONT COOLANT PIPES
• COOLANT PUMP
• After-Run Coolant Pump -V51
• Cooling Circuit Solenoid Valve -N492
• COOLANT DISTRIBUTION HOUSING
• COOLANT THERMOSTAT WITH HOUSING
• Coolant Fan -V7- /Coolant Fan 2 -V177
• FAN SHROUD
• LEFT AUXILIARY COOLER
• COOLANT PUMP AND COOLANT THERMOSTAT WITH HOUSING OVERVIEW
• COOLANT, DRAINING AND FILLING
• RADIATOR AND COOLANT FAN OVERVIEW