Radiator, Removing and Installing Audi TT 8N

Special tools and equipment required

1. Hose clip pliers V.A.G 1921
2. Drip tray V.A.G 1306

1. Open filler cap on coolant expansion tank.

1. Remove fasteners -1- at lock carrier, press pin -2- in approx. 4 mm (do not push in completely). Then pull fastener out upward.

1. Remove covers (left side) -1- and -2- at lock carrier and above main fuse box (arrows).

1. Remove covers (right side) -1- and -2- at lock carrier and above coolant expansion tank (arrows).

1. Remove upper securing bolts (upper arrows) for radiator cowl.

1. Release tension of poly V-belt by screwing an M8 x 40 bolt (arrow) into bore on tensioning element.

Note. Mark the rotation direction of the poly V-belt with chalk or a felt-tipped pen. If the belt runs in the opposite direction when it is reinstalled, breakage can result.

1. Disconnect secondary air hose at position marked with an arrow.
2. Move air hose clear.

1. Remove fasteners -1...3- and remove sound insulation.

1. Remove left sound insulation (arrows).

1. Remove right sound insulation (arrows).

1. Remove cross piece (arrows).

1. Remove power steering pump pulley (counterhold with mandrel).
2. Remove bolts (arrows) and remove power steering pump from bracket.
3. Hang power steering pump on lock carrier with hydraulic hoses -1- and -2- attached.

1. Disconnect electrical connector -1- at Secondary Air Injection (AIR) pump motor -V101-.
2. Move wiring clear.
3. Remove bolt -2- for coolant hose bracket.
4. Remove bolt -3- for secondary air pump air filter.

1. Remove bolts -1- and -2- and remove secondary air pump with bracket -A-.

1. Turn drain plug -1- on radiator counter-clockwise and drain coolant. If necessary, fit auxiliary hose to connection.
2. Release retaining clip -2- for lower coolant hose and disconnect coolant hose from radiator.

1. Disconnect electrical connectors -1- for coolant fans at bottom of radiator cowl.
2. Unscrew lower securing bolts (lower arrows) for radiator cowl.
3. Remove radiator cowl with both fans from below.

Scheme 223

1. Disconnect connector -2- at Coolant Fan Control (FC) thermal switch -F18-.

1. Remove refrigerant line -1- at radiator.

Note. To prevent damage to the condenser and the refrigerant lines/hoses, ensure that lines and hoses are not stretched, kinked or bent.

Scheme 224

1. Remove upper coolant hose -1- at radiator.
2. Remove front bumper cover.

Refer to 63 BUMPERS .

Scheme 225

1. Remove securing bolts -1- for condenser.
2. Remove securing bolts -2- for radiator.
3. Remove Coolant Fan Control (FC) module -J293- at longitudinal member (left side) in front of battery.
4. Remove bolts for lock carrier at front.

1. Loosen upper bolts for lock carrier 2 turns.

Installing

Installation is performed in the reverse order. Note the following

Scheme 226

1. Install brackets -3- and -4- on radiator as shown.
2. Install radiator.
3. Fit securing bolts for radiator (help of a second technician is required).
4. Install secondary air injection pump. Refer to «Secondary air injection pump, removing and installing»(ref-276269-S35561992282008010300000) .

1. Install power steering pump

Refer to 48 STEERING

1. Install cross piece.

Refer to 40 FRONT SUSPENSION

1. Install front bumper cover.

Refer to 63 BUMPERS

1. Replace O-rings in connections for radiator hoses.
2. Fill cooling system. Refer to «Cooling system, draining and filling»(ref-276269-S04050758062008010300000) .

Tightening torques

Scheme 227

Special Tools and Equipment

1. VAG1274 Cooling system tester
2. VAG1274/8 Adapter
3. VAG1274/9 Adapter

Requirement

1. Engine at operating temperature.

Work sequence

1. Open cap of coolant expansion tank.

Scheme 228

1. Attach VAG1274 Cooling System Tester together with VAG1274/8 adapter to coolant expansion tank.
2. Use tester hand pump to create a pressure of approx. 1.0 bar.

If pressure drops

1. Detect leak and repair malfunction.

Scheme 229

1. Attach VAG1274 cooling system tester together with VAG1274/9 adapter to filler cap.
2. Pump using hand pump.

1. Pressure release valve must open at a positive pressure of 1.4 to 1.6 bar.

If the pressure relief valve does not open as described

1. Replace filler cap.