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

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

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

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

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

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

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

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

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

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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 2000 Audi TT
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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 2000 Audi TT
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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 2000 Audi TT
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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 2000 Audi TT
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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 2000 Audi TT
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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