audi Workshop Repair Guides

Audi Workshop Service and Repair Manuals

Parts of cooling system (on engine) - exploded view, engine code AXW, BLX, BHD, BLY, BLR, BMB > < Connection diagram for coolant hoses, engine code BVY, BVZ
Draining and filling cooling system
   
Draining and filling cooling system
Special tools and workshop equipment required
t  Adapter for cooling system tester -V.A.G 1274/8-
t  Drip tray for workshop hoist -VAS 6208-
t  Hose clip pliers -V.A.G 1921-
t  Cooling system charge unit -VAS 6096-
t  Refractometer -T10007-

Draining
  Note
Collect drained coolant in a clean container for re-use or disposal.
  WARNING
Hot steam/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully.
–  Open filler cap on coolant expansion tank
   
–  Remove noise insulation (centre) - fasteners -1 ... 3-.
–  Place drip tray for workshop hoist -VAS 6208- beneath engine.
  A10-1565
–  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection.
  A10-0118
–  Unplug electrical connector -1- from oil pressure sender.
–  Also disconnect bottom coolant hose at coolant pipe -2-, and drain off remaining coolant.
Filling
  Note
t  The cooling system is filled all year round with a mixture of water and coolant additive. Mixture ratio → Anchor.
t  Use only the coolant additive listed in the → Electronic parts catalogue. Other coolant additives could seriously impair in particular the anti-corrosion properties. The resulting damage could lead to loss of coolant and consequently to serious engine damage.
t  The specified coolant (based on recommended mixture ratio) → Anchor prevents frost and corrosion damage and stops scaling. Such additives also raise the boiling point of the coolant. For these reasons the cooling system must be filled all year round with the correct coolant additive.
t  Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.
t  Frost protection is required down to about –25 °C (in countries with arctic climate: down to about –35 °C).
t  The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant concentration must be at least 40 %.
t  If greater frost protection is required in very cold climates, the concentration of coolant additive can be increased, but only up to 60% (this gives frost protection to about –40 °C). If the concentration exceeds 60%, frost protection decreases again and cooling efficiency is also impaired.
t  Use only clean tap water for mixing coolant.
t  If the radiator, heat exchanger, cylinder head, cylinder head gasket or cylinder block have been renewed, do not re-use old the coolant.
t  Contaminated or dirty coolant must not be used again.
t  For checking anti-freeze protection in cooling system, use refractometer -T10007-.
  A19-0391
–  Close drain plug -arrow-.
  A10-0118
–  Attach coolant hose (bottom) at coolant pipe -2-.
–  Plug in the oil pressure sender connector -1-.
  A19-0391
–  Fill reservoir of cooling system charge unit -VAS 6096- with at least 8 litres of premixed coolant (based on recommended ratio) → Anchor
Recommended mixture ratio for coolant
l  Coolant (40 %) and water (60 %) for frost protection to –25 °C
l  Coolant (50 %) and water (50 %) for frost protection to –35 °C
t  Coolant → Electronic parts catalogue
–  Screw adapter for cooling system tester -V.A.G 1274/8- onto coolant expansion tank.
–  Fit cooling system charge unit -VAS 6096- onto adapter for cooling system tester -V.A.G 1274/8-.
–  Run vent hose -1- into a small container -2-. (The vented air draws along a small amount of coolant, which should be collected.)
–  Close the two valves -A- and -B- (levers at right angles to direction of flow).
–  Connect hose -3- to compressed air.
l  Pressure: 6 ... 10 bar
  A19-0351
–  Open valve -B- (lever in direction of flow).
The suction jet pump generates a partial vacuum in the cooling system.
l  The needle on the gauge should move into the green zone.
–  Additionally open valve -A- briefly (lever in direction of flow) so that the hose of cooling system charge unit -VAS 6096- is filled with coolant.
–  Close valve -A- again.
–  Leave valve -B- open for another 2 minutes.
The suction jet pump will continue generating a vacuum in the cooling system.
l  The needle on the gauge should remain in the green zone.
–  Close valve -B-.
l  The needle on the gauge should stop in the green zone. The vacuum level in the cooling system is then sufficient for subsequent filling.
If the needle does not reach the green zone, repeat the process.
If the vacuum level drops, there is a leak in the cooling system.
–  Detach compressed air hose.
–  Open valve -A-.
The vacuum in the cooling system causes the coolant to be drawn out of the cooling system charge unit -VAS 6096-; the cooling system is then filled.
  A19-0353
–  Check the coolant level and top up coolant as far as the max mark.
–  Start engine, run for 2 minutes (maximum) at approx. 1500 rpm and top up coolant to overflow hole on expansion tank with engine running.
–  Fit expansion tank cap.
–  Run engine until radiator fan cuts in.
  WARNING
Hot steam/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully.
–  Check coolant level and top up if necessary. When the engine is at normal operating temperature, the coolant level should be on the max. mark; when the engine is cold, between the min. and max. marks.
–  Switch off engine.
  A19-0480

Parts of cooling system (on engine) - exploded view, engine code AXW, BLX, BHD, BLY, BLR, BMB > < Connection diagram for coolant hoses, engine code BVY, BVZ