1996 AUDI A4 AWM Engine Cooling System Components Workshop Manual

19-1


Cooling system components,
removing and installing

WARNING!

Hot steam can escape when opening the cap
on the expansion tank: Cover the cap with a
cloth and open carefully.

Note:

When the engine is warm the cooling system is
under pressure. If necessary release pressure
before beginning repair work.
Secure all hose connections with the correct
hose clips (same as original equipment):

Parts Catalog

Hose clip pliers VAG 1921 are recommended
when installing spring type clips.
Replace all gaskets and seals.
The arrow markings on the coolant lines and on
the ends of the hoses must be aligned with
each other.
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Removing and installing viscous fan Page 13
-21
.
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19-2


Cooling system diagram

1 -
Radiator
Removing and installing Page 19
-26
After replacing, fill with fresh coolant
2 -
Upper coolant line
3 -
Thermostat Removing and installing coolant pump
Page 19
-12

Checking Page 19
-22
4 -
Coolant pump
Removing and installing Page 19
-12
Check for ease of movement
5 -
Turbocharger
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19-3


6 -
Cylinder head/cylinder block
After replacing, fill with fresh coolant
7 -
Heating system heat exchanger After replacing, fill with fresh coolant
8 -
Lower coolant line Removing and installing Page 19
-23
9 -
Oil cooler
Removing and installing Item 23 ,
Page 17
-10

10 -
Expansion tank
With filler capTesting pressure relief valve in filler cap
Page 19
-33

11 -
Intake manifold
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19-4


Cooling system, draining and filling

Special tools and equipment

Adapter 1274/8
Line VAG 1274/10
Drip tray VAG 1306
Hose clamp pliers VAG 1921
Special tool T10007
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19-5

Draining

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

WARNING!

Hot steam can escape when opening the cap
on the expansion tank: Cover the cap with a
cloth and open carefully.

- Open cover of coolant expansion tank

- Remove sound insulation -arrows-.
- Place drip tray VAG 1306 below engine.

- Remove lower coolant hose retaining clip -arrow- and remove coolant
hose from radiator.
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19-6

Note:

With bumper and air duct in front of charge air cooler removed, the
coolant can also be drained from the radiator via the drain screw -arrow-.
If necessary use an auxiliary hose.

- Disconnect lower coolant hose on oil cooler -arrow-, and drain off
remaining coolant.
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19-7

Filling

Note:

The cooling system is filled all year round with a
mixture of water and an antifreeze/corrosion
protection agent.
Only use coolant additive G 012 A8 D meeting
specification TL VW 774 D. Identification color:
red

CAUTION!

G 012 A8 D and other coolant additives
cannot be mixed. Otherwise, serious damage
to the engine may result.
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 fill with fresh coolant. To
flush the system, fill it with clean water and run
the engine for about 2 minutes. This should
remove as much of the old coolant as possible.
G 012 A8 D and coolant additives marked
"meeting specification TL VW 774 D" prevent
frost and corrosion damage and stop scaling
while at the same time raising the boiling point
of the coolant. For these reasons the cooling
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