2000 Audi TT

2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

2000-2004 ENGINE

Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

COOLING SYSTEM COMPONENTS, REMOVING AND INSTALLING

NOTE: z When the engine is warm the cooling system is under pressure. If
necessary release pressure before commencing repair work.
z Secure all hose connections with hose clamps of the same type as those
installed at the factory.
z VAG 1921 hose clip pliers are recommended when installing spring-type
clips.
z Replace all gaskets and seals.
z The arrow markings on the coolant pipes and on the ends of the hoses
must be aligned with each other.
z Tightening torque for screw clamps: 2 Nm.

Draining and filling cooling system. See COOLING SYSTEM, DRAINING AND FILLING .

Anti-freeze concentration. See FILLING .

See COOLING SYSTEM COMPONENTS .

Checking cooling system for leaks with VAG 1274 and 1274/8. See COOLING SYSTEM, CHECKING
FOR LEAKS .

Removing coolant pump. See COOLANT PUMP, REMOVING AND INSTALLING .

Removing coolant thermostat. See COOLANT THERMOSTAT, REMOVING, INSTALLING AND

CHECKING .

COOLING SYSTEM COMPONENTS

NOTE: The following list refers to items in Fig. 1 .

1. Expansion tank
2. Filler cap for expansion tank
z Testing. See TESTING PRESSURE RELIEF VALVE IN FILLER CAP .

3. Intake manifold
4. Heating system heat exchanger
5. Cylinder block
6. Oil cooler

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

z Removing and installing: See OIL PAN, REMOVING AND INSTALLING , Item 22.
7. Radiator
z After replacing, refill complete system with fresh coolant

8. After-run coolant pump - V51-

z Testing. See AFTER-RUN COOLANT PUMP -V51-, CHECKING .

9. Coolant pump, coolant thermostat

z Removing and installing coolant pump. See COOLANT PUMP, REMOVING AND
INSTALLING .
z Check for ease of movement

z Removing and installing coolant thermostat. See COOLANT THERMOSTAT, REMOVING,

INSTALLING AND CHECKING .
z Testing, operating data. See TESTING COOLANT THERMOSTAT .

10. Turbocharger

Fig. 1: Identifying Cooling System Components & Coolant Flow

Courtesy of AUDI OF AMERICA, INC.

COOLING SYSTEM, DRAINING AND FILLING

Draining

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

NOTE: z Catch drained-off coolant in a clean container for re-use or disposal.

z Coolant must only be mixed with clean drinking water.

z Remove cap from coolant expansion tank.

WARNING: Hot steam can escape when the cap on the expansion tank is
opened. Cover the cap with a cloth, and open it carefully.

z Remove center section of noise insulation.

Fig. 2: Removing Center Section Of Noise Insulation

Courtesy of AUDI OF AMERICA, INC.

z Place drip tray VAG 1306 below engine.

z Turn drain screw -arrow- on radiator anti-clockwise, install an extension hose to the connection if
necessary.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 3: Locating Radiator Drain Screw

Courtesy of AUDI OF AMERICA, INC.

z Also disconnect coolant hose at bottom of oil cooler -arrow-, and drain off remaining coolant.

Fig. 4: Locating Coolant Hose At Bottom Of Oil Cooler

Courtesy of AUDI OF AMERICA, INC.

Filling

NOTE: z Only use coolant additive G 012 A8 D - meeting specification TL VW 774 D.

Identifiable by red color

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

CAUTION: Do not use G 011 A8 C. The two different coolant additives G 011 A8 C and
G 012 A8 D must not be mixed together. Otherwise this can result in
serious damage to the engine.

z If the fluid in the expansion tank is brown, this means G 012 A8 D has
been mixed with another type of coolant. In this case, flush out the
cooling system and put in fresh coolant. To flush the system, fill it
with clean water and run the engine for about 2 minutes. This should
remove very nearly all of the old coolant.
z G 012 A8 D and coolant additives marked "meeting specification TL
VW 774 D" prevent frost and corrosion damage, stop scaling and at
the same time raise the boiling point of coolant. For these reasons
the cooling system must be filled all year round with the correct
antifreeze and anti-corrosion additive.
z Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with tropical
climates.
z Frost protection is required down to about -25° C (in countries with
arctic climates down to about -35° C).
z The coolant concentration must not be reduced by adding water even
in warmer seasons and in warmer countries. The anti-freeze ratio
must be at least 40 %.
z If greater frost protection is required in very cold climates, the
amount of G 012 A8 D can be increased, but only up to 60 % (this
gives frost protection to about -40° C), as otherwise frost protection
is reduced again and cooling effectiveness is also reduced.
z If radiator, heat exchanger, cylinder head or cylinder head gasket is
replaced, do not reuse old coolant.

Recommended mixture ratios:

COOLANT MIXTURE RATIOS

Frost protection to Anti-freeze concentration Quantity of G 012A8 D (1) Quantity of water()
-25° C 40 % 2.0 ltr. 3.0 ltr.
-35° C 50 % 2.5 ltr. 2.5 ltr.
(1) Coolant quantity: 5.0 liters (may vary depending upon the vehicle equipment).

z Screw in coolant drain plug.

z Top up coolant to max. mark on expansion tank.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 5: Identifying Maximum Mark Of Coolant

Courtesy of AUDI OF AMERICA, INC.

z Start engine and run at approx. 1500 RPM for max. 2 minutes and at the same time fill with coolant up to
overflow hole on expansion tank.
z Install expansion tank cap.
z Run engine until radiator fan cuts in.
z Stop engine.
z Check coolant level and top-up if necessary. When the engine is at normal operating temperature, the
coolant level must be on the max. mark, when the engine is cold, between the min. and max. marks.

WARNING: Hot steam can escape when the cap on the expansion tank is opened.
Cover the cap with a cloth, and open it carefully.

AFTER-RUN COOLANT PUMP -V51-, CHECKING

NOTE: After-run coolant pump -V51- is located on the fan cowl to the right of the
radiator fan.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 6: Identifying V51 Coolant Pump

Courtesy of AUDI OF AMERICA, INC.

z Switch on ignition.

After-run coolant pump -V51- should start running (pump can be felt and heard).

If pump does not run:

Check fuse and wiring according to wiring diagram.

If the fuse is OK and there is no open circuit in the wiring:

Replace after-run coolant pump -V51-

COOLANT PUMP, REMOVING AND INSTALLING

NOTE: Always replace seals and gaskets.

Removing

z Remove engine cover.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 7: Removing Engine Cover

Courtesy of AUDI OF AMERICA, INC.

z Drain cooling system. See COOLING SYSTEM, DRAINING AND FILLING .

z Remove center and right-hand sections of noise insulation -arrows-.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 8: Removing Center And Right-Hand Sections Of Noise Insulation

Courtesy of AUDI OF AMERICA, INC.

z Remove ribbed belt and tensioning element. See RIBBED BELT, REMOVING AND INSTALLING .
z Disconnect vacuum hose from activated charcoal filter and from throttle valve connection.
z Remove coolant expansion tank (see left-hand arrows) together with hoses.
z Unbolt power steering reservoir (see right-hand arrow). Do not disconnect the hoses.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 9: Removing Coolant Expansion Tank Together With Hoses

Courtesy of AUDI OF AMERICA, INC.

z Remove toothed belt guards (upper and center). See TOOTHED BELT, REMOVING AND
INSTALLING .
z Set crankshaft to markings for TDC of No. 1 cylinder - arrows- by turning central bolt on crankshaft
sprocket in direction of rotation.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 10: Aligning Camshaft Sprocket And Vibration Damper Timing Marks
Courtesy of AUDI OF AMERICA, INC.

z Screw M5x55 stud -1- into toothed belt tensioning element. Screw hex nut -2- onto stud -1 - using a large
washer -3-. See Fig. 11 .
z Tension pressure piston of tensioning element only until it can be secured with a locking pin (e.g. from
lifting appliance 2024 A) -arrow-.

Fig. 11: Locating Toothed (Timing) Belt Tensioning Element

Courtesy of AUDI OF AMERICA, INC.

NOTE: If it is not possible to insert the locking pin, carefully tension the pressure
piston of the tensioning element just enough to allow the toothed belt to
be removed.

z Take toothed belt off camshaft sprocket.

NOTE: z The vibration damper and bottom toothed belt guard do not have to
be removed.
z The toothed belt should be left in position on the crankshaft
sprocket.
z Cover toothed belt with a cloth to protect it from coolant before
removing coolant pump.

z Remove coolant pump securing bolts -1- and remove coolant pump -2-.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 12: Removing Coolant Pump

Courtesy of AUDI OF AMERICA, INC.

Installing

Installation is carried out in the reverse order, when doing this note the following:

z Clean and smooth down sealing surface for O-ring as required.

z Moisten new O-ring with coolant G 012 A8 D.
z Install coolant pump. Installation position: plug in housing faces downward.
z Install toothed belt (adjust valve timing). See TOOTHED BELT, REMOVING AND INSTALLING .

NOTE: Follow all the instructions on removing and installing the toothed belt. See
TOOTHED BELT, REMOVING AND INSTALLING .

z Installing ribbed belt and tensioning element. See ENGINE, DISASSEMBLING AND
ASSEMBLING .
z Fill up with coolant. See FILLING .

Tightening torque

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

TIGHTENING TORQUE: COOLANT PUMP

Component Nm
Coolant pump to cylinder block 15

COOLANT THERMOSTAT, REMOVING, INSTALLING AND CHECKING

Removing

NOTE: z Always replace seals and gaskets.

z Obtain radio anti-theft code on vehicles with coded radio.
z Secure all hose connections with hose clamps of the same type as those
installed at the factory.

z With the ignition switched off, disconnect the battery Ground strap.
z Drain cooling system. See COOLING SYSTEM, DRAINING AND FILLING .
z Detach coolant hose at bracket for solenoid valves above alternator.
z Unbolt bracket for solenoid valves -2- and -3- in front of intake manifold and detach dipstick guide tube -
4-.

Fig. 13: Detaching Dipstick Guide Tube

Courtesy of AUDI OF AMERICA, INC.

z Pull connector-3-and vacuum hose-1-out of bracket.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 14: Removing Connector And Vacuum Hose From Bracket

Courtesy of AUDI OF AMERICA, INC.

z Lay bracket clear to the side without detaching remaining connections.

z Disconnect coolant hose from elbow connection -3-. See Fig. 15 .
z Remove bolts -4- and take off elbow connection, O-ring and thermostat -1-.

Fig. 15: Exploded View Of Thermostat And Housing

Courtesy of AUDI OF AMERICA, INC.

Installing

z Clean and smooth down sealing surface for O-ring as required.

z Insert coolant thermostat. Installation position: bowed metal strip on thermostat must be vertical.
z Moisten new O ring with coolant G 012 A8 D.
z Tighten bolts.
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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

z Fill up with coolant. See FILLING .

Tightening torque

TIGHTENING TORQUE: THERMOSTAT HOUSING

Component Nm
Elbow connection to cylinder block 15
Bracket for solenoid valves to intake manifold 10

z After connecting battery terminals, enter anti-theft code for radio

See Radio operating instructions .

WARNING: If a battery charger is used to give the engine an assisted start, there
is a risk that the control units in the vehicle will be damaged.

z Close electric windows in front doors all the way to their top positions using electric switches.
z Then operate all electric window switches again for at least one second in the "close" direction to activate
the automatic one-touch function.
z Set clock to correct time.
z Interrogate DTC memory:

See CHECK DTC MEMORY (SCAN TOOL FUNCTION 02) AND ERASE DTC MEMORY
(SCAN TOOL FUNCTION 05) .

NOTE: DTCs will have been stored in the memory because connectors have been
disconnected. Therefore interrogate and erase DTC memory after installing
engine.

Testing coolant thermostat

z Heat thermostat in water bath.

COOLANT THERMOSTAT OPENING SPECIFICATIONS

Starts to open Fully open Opening travel
approx. 87° C approx. 102° C () at least 7 mm
(1) cannot be tested

COOLANT LINE, REMOVING AND INSTALLING

Removing

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

NOTE: Always replace seals and gaskets.

z Obtain radio anti-theft code on vehicles with coded radio.

z With the ignition switched off disconnect the battery Ground strap.
z Drain cooling system. See COOLING SYSTEM, DRAINING AND FILLING .
z Remove intake manifold. See INTAKE MANIFOLD, REMOVING AND INSTALLING .
z Disconnect air duct -4- from air mass meter. See Fig. 16 .
z Disconnect electrical connectors for air mass meter -1-.
z Remove bolts -2- and -3- and take off air cleaner housing.

Fig. 16: Disconnecting Air Duct From Air Mass Sensor And Electrical Connector, Air Cleaner
Housing
Courtesy of AUDI OF AMERICA, INC.

z Detach air intake hose from connection on turbocharger as follows:

{ Disconnect vacuum hose -1- from air recirculation valve. See Fig. 17 .

{ Disconnect hose from pressure control valve for crankcase breather -2-.

{ Disconnect electrical connector from charge pressure control valve -3- (-N75-). See Fig. 17 .

z Disconnect hose -4- from charge pressure control valve -N75-.

z Disconnect hose -5- at bulkhead (hose leads from solenoid valve to turbocharger). See Fig. 17 .
{ Take solenoid charge pressure control valve out of air intake hose and place it to one side on the
engine.
{ Pull retainer off turbocharger connection and detach air intake hose.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 17: Detaching Air Intake Hose At Turbocharger And Electrical Connections
Courtesy of AUDI OF AMERICA, INC.

z Disconnect coolant hose from coolant line (hose leads to heat exchanger for heater).

Vehicles with automatic transmission

z Disconnect connectors:

1. for solenoid valves (10-pin connector)

2. for road speed sender -G68-

Fig. 18: Disconnecting Connectors For Solenoid Valves (10-Pin Connector) And Road Speed Sender -
G68-
Courtesy of AUDI OF AMERICA, INC.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

All vehicles:

z Unbolt coolant pipe retainer from coolant line flange on left of cylinder head.
z Disconnect hose (leading to oil cooler) from coolant line.
z Remove crankcase breather line.
z Unbolt coolant line retainer from cylinder block.
z Disconnect hose (leading to coolant expansion tank) from coolant line (right).
z Unbolt coolant line retainer from tensioning element for ribbed belt.
z Pull tapered collar off oil dipstick tube.
z Disconnect wires/connectors as follows:
{ Knock sensor I -G61-

{ Engine speed sensor -G28- (middle, grey)

{ Knock sensor II-G66-

z Take connectors out of retainer.

z Remove oil line leading to turbocharger and unbolt retainer for oil line (both are attached to the oil filter
bracket).
z Unbolt retainer for connectors.
z Unbolt knock sensors I and II.
z Unbolt left-hand coolant line flange from cylinder head.
z Detach coolant line.

Installing

Installation is carried out in the reverse order, when doing this note the following:

z Before installing, clean and smooth down sealing surface for O-ring as required.
z Moisten new O-ring -1 - with G 012 A8 D and slide onto coolant pipe -2-.

Fig. 19: Installing New O Ring Onto Coolant Pipe

Courtesy of AUDI OF AMERICA, INC.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

z Push coolant pipe into opening in cylinder block.

z Fill up with coolant. See FILLING .
z After connecting battery terminals, enter anti-theft code for radio.

See Radio operating instructions .

z Close electric windows in front doors all the way to their top positions using electric switches.
z Then operate all electric window switches again for at least one second in the "close" direction to activate
the automatic one-touch function.
z Set clock to correct time.
z Interrogate DTC memory:

See CHECK DTC MEMORY (SCAN TOOL FUNCTION 02) AND ERASE DTC MEMORY
(SCAN TOOL FUNCTION 05) .

NOTE: DTCs will have been stored in the memory because connectors have been
disconnected. Therefore interrogate and erase DTC memory after installing
engine.

Tightening torques

TIGHTENING TORQUES: COOLANT LINE BRACKET

Component Nm
Coolant line bracket to cylinder block 10
Coolant line bracket to oil filter bracket 20
Coolant line bracket to coolant line flange 10

RADIATOR, REMOVING AND INSTALLING

NOTE: Always replace gaskets and seals.

Removing

z Obtain radio anti-theft code on vehicles with coded radio.

z With ignition switched off disconnect battery Ground strap.
z Remove noise insulation -arrows-.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 20: Removing Noise Insulations

Courtesy of AUDI OF AMERICA, INC.

z Drain cooling system. See COOLING SYSTEM, DRAINING AND FILLING .

z Release clamps and disconnect coolant hoses from connections on radiator (top and bottom).
z Remove front bumper:

See FRONT BUMPER .

NOTE: Only remove the cover section for the front bumper.

z Disconnect connectors -1- on radiator fan cowl. See Fig. 21 .

z Disconnect connector -2- from coolant Fan Control (FC) thermal switch -F18-.
z Unbolt radiator cowl -3- together with radiator fans (4 bolts) and pull downward to remove. See Fig. 21 .

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 21: Removing Radiator

Courtesy of AUDI OF AMERICA, INC.

Vehicles without air conditioner:

z Remove the 4 securing bolts -arrows- on the radiator.

Fig. 22: Locating Securing Bolts On Radiator

Courtesy of AUDI OF AMERICA, INC.

z Lower radiator out of vehicle.

Vehicles with air conditioner:

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

z Remove the four securing bolts -1 - for the condenser.

z Remove the four securing bolts -2- for the radiator.

Fig. 23: Removing Securing Bolts For Condenser And Radiator

Courtesy of AUDI OF AMERICA, INC.

WARNING: The air conditioner refrigerant circuit must not be opened.

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

z Unbolt radiator fan control unit -J293- from left-hand longitudinal member (in front of battery).
z Carefully lower radiator between engine and condenser and remove from below.

Installing

Installation is carried out in the reverse order, when doing this note the following:

z Install mounts -3- and -4- on radiator as illustrated.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

Fig. 24: Installing Radiator Mounts

Courtesy of AUDI OF AMERICA, INC.

z Install radiator securing bolts (the help of a 2nd mechanic is required).

z Install front bumper:

See FRONT BUMPER .

z Replace O rings in the coolant hose connections.

z Fill up with coolant. See FILLING .
z After connecting battery terminals, enter anti-theft code for radio.

See Radio operating instructions.

z Close electric windows in front doors all the way to their top positions using electric switches.
z Then operate all electric window switches again for at least one second in the "close" direction to activate
the automatic one-touch function.
z Set clock to correct time.
z Interrogate DTC memory:

See CHECK DTC MEMORY (SCAN TOOL FUNCTION 02) AND ERASE DTC MEMORY
(SCAN TOOL FUNCTION 05) .

NOTE: DTC will have been stored in the memory because connectors have been
disconnected. Therefore interrogate and erase DTC memory after installing

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

engine.

Tightening torques

TIGHTENING TORQUES: RADIATOR

Components Nm
Radiator fan cowl to radiator 10
Thermal switch to radiator 35
Radiator to lock carrier 10
Condenser to radiator 10
Control unit to longitudinal member 10

COOLING SYSTEM, CHECKING FOR LEAKS

Test requirement:

z Engine at operating temperature.

WARNING: Hot steam can escape when the cap on the expansion tank is opened.
Cover the cap with a cloth, and open it carefully.

z Remove cap from coolant expansion tank.

z Install tester VAG 1274 with adapter VAG 1274/8 onto expansion tank.

Fig. 25: Installing VAG 1274 With Adapter Vag 1274/8 Onto Expansion Tank
Courtesy of AUDI OF AMERICA, INC.

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 2000 Audi TT
2000-2004 ENGINE Engine Cooling System, 1.8L 4Cyl. 5V Turbo: AMU, BEA - TT

z Using hand pump on tester, build up a pressure of approx. 1.0 bar.

z If this pressure drops, locate the leak and repair.

Testing pressure relief valve in filler cap

z Screw filler cap onto tester with adapter VAG 1274/9.

Fig. 26: Checking Pressure Relief Valve In Filler Cap

Courtesy of AUDI OF AMERICA, INC.

z Attach hand pump and build up pressure.

z The pressure relief valve should open at a pressure of 1.4 -1.6 bar.

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 2000 Audi TT
2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

2004 ENGINE

Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

ENGINE COOLANT SYSTEM COMPONENTS, REMOVING AND INSTALLING

NOTE: z When the engine is warm the coolant system is under pressure. If
necessary release pressure before commencing repair work.
z Secure all hose connections with hose clamps of the same type as those
installed at the factory.

See Parts catalog

z V.A.G 1921 hose clip pliers are recommended when installing spring-type
clips.
z Replace all gaskets and seals.
z The arrow markings on the coolant lines and on the ends of the hoses
must be aligned with each other.
z Draining and filling coolant system, see ENGINE COOLANT SYSTEM,
DRAINING AND FILLING .
z Anti-freeze concentration, see FILLING .
z Coolant Hose Connection Diagram, see ENGINE COOLANT SYSTEM
COMPONENTS, OVERVIEW .
z Checking coolant system for leaks with V.A.G 1274 and 1274/8, see
COOLANT SYSTEM, CHECKING FOR LEAKS .
z Removing coolant pump, see COOLANT PUMP, REMOVING AND
INSTALLING .
z Removing coolant thermostat, see COOLANT THERMOSTAT, CHECKING,
REMOVING AND INSTALLING

ENGINE COOLANT SYSTEM COMPONENTS, OVERVIEW

The following list pertains to Fig. 1 .

1. Radiator
z After replacing replace entire coolant

2. 2 -Oil cooler
z Removing and installing, see LUBRICATION SYSTEM COMPONENTS, PART II , item 22

3. Coolant pump, coolant thermostat

z Removing and installing coolant pump, see COOLANT PUMP, REMOVING AND
INSTALLING
„ Check for ease of movement.

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 2000 Audi TT
2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

zRemoving and installing coolant thermostat, see COOLANT THERMOSTAT, CHECKING,

REMOVING AND INSTALLING
z Testing, operating data, see TESTING COOLANT THERMOSTAT

4. Cylinder block
5. Expansion tank
z Checking filler cap, see TESTING PRESSURE RELIEF VALVE IN FILLER CAP

6. Turbocharger
7. Intake manifold
8. Heating system heat exchanger
9. Transmission oil cooler
z For ATF in automatic transmission

Fig. 1: Identifying Coolant System Components And Coolant Flow Diagram

Courtesy of AUDI OF AMERICA, INC.

ENGINE COOLANT SYSTEM, DRAINING AND FILLING

Draining

NOTE: z Collect drained coolant in a clean container for re-use or disposal.

z Coolant must only be mixed with clean drinking water.

z Remove cap from coolant expansion tank.

WARNING: Hot steam can escape when the cap on the expansion tank is
opened. Cover the cap with a cloth, and open it carefully.

z Remove center noise insulation panel.

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Fig. 2: Removing Center Noise Insulation Panel

Courtesy of AUDI OF AMERICA, INC.

z Place drip tray V.A.G 1306 below engine.

z Turn drain screw -arrow- on radiator counter-clockwise (install an extension hose to the connection if
necessary).

Fig. 3: Identifying Radiator Drain Screw

Courtesy of AUDI OF AMERICA, INC.

z also disconnect bottom coolant hose from oil cooler -arrow- and drain off remaining coolant.

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Fig. 4: Disconnecting Bottom Coolant Hose From Oil Cooler

Courtesy of AUDI OF AMERICA, INC.

Filling

NOTE: z Only use coolant additive G 012 A8 D which meets specification TL VW

774 D (identifiable by red color).

CAUTION: Do not use G 011A8 C. The two different coolant additives G 011 A8C and
G 012 A8 D must not be mixed together. Otherwise this can result in
serious damage to the engine.

z If the fluid in the expansion tank is brown it means G 012 A8 D has been mixed with another type of
coolant. In this case, flush out the coolant system and put in fresh coolant. To flush the system, fill it with
clean drinking water and run the engine for about 2 minutes. This should remove very nearly all of the
old coolant.
z G 012 A8 D and coolant additives marked "meeting specification TL VW 774 D" prevent frost and
corrosion damage, stop scaling, and at the same time raise the boiling point of coolant. For these reasons
the coolant system must be filled all year round with the correct antifreeze and anti-corrosion additive.
z Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly
in countries with tropical climates.
z Frost protection is required down to about -25 ° C (or to about -35 ° C in countries with arctic climates).
z The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer
countries. The anti-freeze ratio must be at least 40%.
z If greater frost protection is required in very cold climates, the amount of G 012 A8 D can be increased,
but only up to 60% (this gives frost protection to about -40 ° C), as otherwise frost protection is reduced
again and cooling effectiveness is also reduced.

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

z If the radiator, heat exchanger, cylinder head or cylinder head gasket are replaced, do not re-use old
coolant.

Recommended mixture ratios:

RECOMMENDED COOLANT MIXTURE RATIOS

Frost protection to Anti-freeze concentration Quantity of G 012A8 D(1) Quantity of water(1)
-25 ° C 40% 2.0 ltr. 3.0 ltr.
-35 ° 50% 2.5 ltr. 2.5 ltr
(1) Coolant quantity: 5.0 liters (may vary depending upon the vehicle equipment).

NOTE: Use clean drinking water in addition to coolant to top off coolant system.

z Screw in coolant drain plug.

Fig. 5: Identifying Max Mark On Expansion Tank

Courtesy of AUDI OF AMERICA, INC.

z Top up coolant to max. mark on expansion tank.

z Start engine and run at approx. 1500 rpm for max. 2 minutes and at the same time fill with coolant up to
overflow hole on expansion tank.
z Install expansion tank cap.
z Run engine until radiator fan cuts in.
z Stop engine.

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z Check coolant level and top-up if necessary.

z When the engine is at normal operating temperature, the coolant level must be on the max. mark

z When the engine is cold, coolant level must be between the min. and max. marks

WARNING: Hot steam can escape when the cap on the expansion tank is opened.
Cover the cap with a cloth, and open it carefully.

COOLANT PUMP, REMOVING AND INSTALLING

NOTE: Always replace seals and gaskets.

Removing

z Remove engine cover.

Fig. 6: Removing Engine Cover

Courtesy of AUDI OF AMERICA, INC.

z Disconnect air duct at bottom of right-hand longitudinal member (air duct leads to charge air cooler).

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Fig. 7: Disconnecting Air Duct At Bottom Of Right-Hand Longitudinal Member

Courtesy of AUDI OF AMERICA, INC.

z Drain coolant system. See ENGINE COOLANT SYSTEM, DRAINING AND FILLING .

Fig. 8: Removing Center And Right-Hand Sections Of Noise

Courtesy of AUDI OF AMERICA, INC.

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z Remove center and right-hand sections of noise insulation -arrows-.

z Remove ribbed belt and tensioning element. See ENGINE, DISASSEMBLING AND ASSEMBLING .
z Disconnect vacuum hose from activated charcoal filter and from throttle valve connection.
z Remove coolant expansion tank (left arrows) together with hoses.

Fig. 9: Removing Coolant Expansion Tank

Courtesy of AUDI OF AMERICA, INC.

z Unbolt power steering reservoir (right arrow). Do not disconnect the hoses.
z Remove toothed belt guards (upper and center). See TOOTHED BELT, REMOVING AND
INSTALLING .
z Set crankshaft to markings for TDC of No. 1 cylinder -arrows- by turning central bolt on crankshaft
sprocket in direction of rotation.

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Fig. 10: Identifying Crankshaft And Camshaft Markings For TDC Of No. 1 Cylinder
Courtesy of AUDI OF AMERICA, INC.

z Screw M5x55 stud -1- into toothed belt tensioning element. Screw hex nut -2- onto stud -1- using large
washer -3-.

Fig. 11: Screwing M5x55 Stud -1- Into Toothed Belt Tensioning Element
Courtesy of AUDI OF AMERICA, INC.

z Tension pressure piston of tensioning element only until it can be secured with a locking pin (for
example, from lifting appliance 2024 A) -arrow-.

NOTE: If it is not possible to insert the locking pin, carefully tension the pressure
piston of the tensioning element just enough to allow the toothed belt to
be removed.

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z Remove toothed belt from camshaft sprocket.

NOTE: z The vibration damper and bottom toothed belt guard do not have to
be removed.
z The toothed belt should be left in position on the crankshaft
sprocket.
z Cover toothed belt with a cloth to protect it from coolant before
removing coolant pump.

Vehicles with air conditioning:

z Remove lower air duct (see CHARGE AIR COOLING SYSTEM COMPONENTS, REMOVING
AND INSTALLING , item 11).

All models

z Remove coolant pump securing bolts-1-and remove coolant pump -2-.

Fig. 12: Identifying Coolant Pump Bolts

Courtesy of AUDI OF AMERICA, INC.

Installing

Installation is carried out in the reverse order, noting the following:

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z Clean and smooth down sealing surface for O-ring as required.

z Moisten new O-ring with coolant G 012 A8 D.
z Install coolant pump. Installation position: plug in housing faces downward.
z Install toothed belt (adjust valve timing). See INSTALLING TOOTHED BELT (SETTING
CAMSHAFT TIMING)

NOTE: Follow all the instructions on removing and installing the toothed belt. See
TOOTHED BELT, REMOVING AND INSTALLING .

z Install ribbed belt and tensioning element. See ENGINE, DISASSEMBLING AND ASSEMBLING .
z Fill up with coolant. See FILLING .

Tightening torques

TIGHTENING TORQUES: COOLANT PUMP

Component Ft-lbs. Nm
Coolant pump to cylinder block 11 15

COOLANT THERMOSTAT, CHECKING, REMOVING AND INSTALLING

NOTE: Always replace seals and gaskets.

Removing

z Drain coolant system. See ENGINE COOLANT SYSTEM, DRAINING AND FILLING .

Vehicles with air conditioning:

WARNING: The air conditioning refrigerant circuit must not be opened.

z Unbolt front engine cover support from intake manifold.

z Detach retainers for refrigerant hoses.
z Unbolt A/C compressor, lift clear together with refrigerant hoses (do not disconnect) and tie in place on
hood lock.

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Fig. 13: Identifying A/C Compressor Bolts

Courtesy of AUDI OF AMERICA, INC.

All vehicles:

z Disconnect coolant hose from connection -3-. See Fig. 14 .

z Remove bolts -4- and remove connection, O-ring -2- and coolant thermostat -1 -.

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Fig. 14: Exploded View Of Thermostat And Housing

Courtesy of AUDI OF AMERICA, INC.

Installing

z Clean and smooth down sealing surface for O-ring as required.

z Insert coolant thermostat.
z Installation position: bowed metal strip on thermostat must be vertical.
z Moisten new O ring with coolant G 012 A8 D.
z Tighten bolts.
z Fill up with coolant. See FILLING .

Tightening torque

Connection (thermostat housing) to cylinder block: 15 Nm (11 ft-lbs.)

Testing coolant thermostat

z Heat thermostat in water bath.

THERMOSTAT OPENING SPECIFICATIONS

Starts to open Fully open Opening travel
approx. 87 ° C approx. 102 ° C(1) at least 7 mm
(1) Cannot be tested.

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COOLANT LINE, REMOVING AND INSTALLING

Removing

NOTE: Always replace seals and gaskets.

z Obtain radio anti-theft code on vehicles with coded radio.

z With the ignition switched off, disconnect the battery Ground strap.
z Drain coolant system. See ENGINE COOLANT SYSTEM, DRAINING AND FILLING .
z Remove intake manifold. See INTAKE MANIFOLD, REMOVING AND INSTALLING .
z Disconnect air duct -4- from air mass meter. See Fig. 15 .
z Disconnect electrical connectors for air mass meter -1-.
z Remove bolts -2- and -3- and take off air cleaner housing.

Fig. 15: Removing Air Cleaner Housing

Courtesy of AUDI OF AMERICA, INC.

Detach air intake hose from connection on turbocharger as follows:

z Disconnect vacuum hose -1- from air recirculation valve. See Fig. 16 .
z Disconnect hose from pressure control valve for crankcase breather -2-.
z Disconnect electrical connector from charge pressure control valve -3- -N75. See Fig. 16 .
z Disconnect hose -4- from charge pressure control valve -N75-. See Fig. 16 .
z Disconnect hose -5- at bulkhead (hose leads from solenoid valve to turbocharger).

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Fig. 16: Disconnecting Air Intake Hose From Connection On Turbocharger

Courtesy of AUDI OF AMERICA, INC.

z Take solenoid charge pressure control valve out of air intake hose and place it to one side on the engine.
z Pull retainer off turbocharger connection and detach air intake hose.
z Disconnect coolant hose from coolant line (hose leads to heat exchanger for heater).

Vehicles with automatic transmission

z Disconnect connectors:
1. for solenoid valves (10-pin connector). See Fig. 17 .
2. for road speed sensor -G68-

Fig. 17: Disconnecting Connectors

Courtesy of AUDI OF AMERICA, INC.

All vehicles:

z Unbolt line retainer from coolant line flange on left of cylinder head.
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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

z Disconnect hose (leading to oil cooler) from coolant line.

z Remove crankcase breather line.
z Unbolt coolant line retainer from cylinder block.
z Disconnect hose (leading to coolant expansion tank) from coolant line (right).
z Unbolt coolant line retainer from tensioning element for ribbed belt.
z Pull tapered collar off oil dipstick tube.
z Disconnect wires/unplug connectors as follows:
z Knock sensor I -G61-

z Engine speed sensor -G28- (middle, grey)

z Knock sensor II-G66-

z Take connectors out of retainer.

z Remove oil line leading to turbocharger and unbolt retainer for oil line (both are attached to the oil filter
bracket).
z Unbolt retainer for connectors.
z Unbolt knock sensors I and II.
z Unbolt left-hand coolant line flange from cylinder head.
z Detach coolant line.

Installing

Installation is carried out in the reverse order, noting the following:

z Before installing, clean and smooth down sealing surface for O-ring as required.

Fig. 18: Installing O-Ring On To Coolant Line

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Courtesy of AUDI OF AMERICA, INC.

z Moisten new O-ring -1- with G 012 A8 D and slide onto coolant line -2-.
z Push coolant line into opening in cylinder block.
z Fill up with coolant. See FILLING .
z After connecting battery terminals, enter anti-theft code for radio.

See Radio operating instructions.

z Close electric windows in front doors all the way to their top positions using electric switches.
z Operate all electric window switches again for at least one second in the "close" direction to activate the
automatic one-touch function.
z Set clock to correct time.
z Check DTC memory.

See DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, CHECKING AND ERASING (engine
code ATC), or DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, CHECKING AND ERASING
(engine code AWP).

NOTE: DTCs will be stored in the memory because connectors have been unplugged.
Therefore, check and erase DTC memory after installing the engine.

Tightening torques

TIGHTENING TORQUES: COOLANT LINE BRACKET

Component Ft-lbs. Nm
Coolant line bracket to cylinder block 7 10
Coolant line bracket to oil filter bracket 15 20
Coolant line bracket to coolant line flange 7 10

RADIATOR, REMOVING AND INSTALLING

NOTE: Always replace gaskets and seals.

Removing

z Obtain radio anti-theft code on vehicles with coded radio.

z With ignition switched off, disconnect battery Ground strap.

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Fig. 19: Removing Noise Insulation

Courtesy of AUDI OF AMERICA, INC.

z Remove noise insulation -arrows-.

z Drain coolant system, see ENGINE COOLANT SYSTEM, DRAINING AND FILLING
z Release clamps and disconnect coolant hoses from connections on radiator (top and bottom).
z Remove front bumper (cover section only).

See FRONT BUMPER .

NOTE: Only remove the cover section for the front bumper.

z Disconnect connectors -1- on radiator cowl. See Fig. 20 .

z Disconnect connector -2- from thermoswitch -F18-.
z Unbolt radiator cowl -3- together with radiator fans (4 bolts) and pull downward to remove.

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Fig. 20: Removing Radiator

Courtesy of AUDI OF AMERICA, INC.

Vehicles without air conditioning:

z Remove the 4 securing bolts -arrows- on the radiator.

Fig. 21: Removing Radiator Securing Bolts (Vehicles Without Air Conditioning)
Courtesy of AUDI OF AMERICA, INC.

z Lower radiator out of vehicle.

z Remove the four securing bolts -1- for the condenser. See Fig. 22 .

Vehicles with air conditioning:

z Remove the four securing bolts -2- for the radiator.

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Fig. 22: Removing Securing Bolts For Condenser And Radiator

Courtesy of AUDI OF AMERICA, INC.

WARNING: The air conditioning refrigerant circuit must not be opened.

NOTE: To prevent damage to the condenser and refrigerant lines/hoses, ensure

that the lines and hoses are not stretched, kinked or bent.

z Unbolt radiator fan control unit -J293- from left-hand longitudinal member (in front of battery).
z Carefully lower radiator between engine and condenser and remove from below.

Installing

Installation is carried out in the reverse order, noting the following:

z Install mountings -3- and -4- on radiator as illustrated in Fig. 23 .

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Fig. 23: Installing Radiator

Courtesy of AUDI OF AMERICA, INC.

z Install radiator securing bolts (the help of a 2nd technician is required).

z Install front bumper.

See FRONT BUMPER .

z Replace O-rings in the coolant hose connections.

z Fill up with coolant, see FILLING .
z After connecting battery terminals, enter anti-theft code for radio.

See Radio operating instructions

z Close electric windows in front doors all the way to their top positions using electric switches.
z Operate all electric window switches again for at least one second in the "close" direction to activate the
automatic one-touch function.
z Set clock to correct time.
z Check DTC memory.

See DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, CHECKING AND ERASING (engine
code ATC), or DIAGNOSTIC TROUBLE CODE (DTC) MEMORY, CHECKING AND ERASING
(engine code AWP).

NOTE: DTCs will be stored in the memory because connectors have been
unplugged. Therefore, check and erase DTC memory after installing the
engine.

Tightening torques

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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

TIGHTENING TORQUES: RADIATOR

Components Ft-lbs. Nm
Radiator cowl to radiator 7 10
Thermoswitch to radiator 26 35
Radiator to lock carrier 7 10
Condenser to radiator 7 10
Control unit to longitudinal member 7 10

COOLANT SYSTEM, CHECKING FOR LEAKS

Test requirement

z Engine at operating temperature

WARNING: Hot steam can escape when the cap on the expansion tank is opened.
Cover the cap with a cloth, and open it carefully.

z Remove cap from coolant expansion tank.

z Install tester V.A.G 1274 with adapter V.A.G 1274/8 onto expansion tank.

Fig. 24: Installing Tester V.A.G 1274 With Adapter V.A.G 1274/8 Onto Expansion Tank
Courtesy of AUDI OF AMERICA, INC.

z Using hand pump on tester, build up a pressure of approx. 1.0 bar.

z If this pressure drops, locate the leak and repair the malfunction.
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2004 ENGINE Engine Cooling System (1.8L 4Cyl. 5V Turbo) - ATC, AWP - TT

Testing pressure relief valve in filler cap

z Screw filler cap onto tester with adapter V.A.G 1274/9.

Fig. 25: Connecting Filler Cap Onto Tester With Adapter V.A.G 1274/9
Courtesy of AUDI OF AMERICA, INC.

z Attach hand pump and build up pressure.

The pressure relief valve should open at a pressure of 1.4-1.6 bar.

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