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Cooling system components, removing and installing

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Cooling system components, removing and installing


WARNING! When doing any repair work, especially in the engine compartment, due to the cramped conditions, pay attention to the following: Route all sorts of pipes (e.g. for fuel, hydraulics, evaporative emissions system, coolant, refrigerant, brake fluid and vacuum pipes and hoses) and electrical wiring so that the original positions are restored. Make sure sufficient clearance to all moving or hot components. Note: When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Hoses are secured with spring-type clips. In cases of repair only use spring-type clips. Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended for installing spring-type clips. When installing coolant hoses route stress-free, so that they do not come into contact with other components (observe markings on coolant connection and hose).

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Cooling system components, removing and installing

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Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and V.A.G 1274/9. Parts of cooling system body side 19-3 . Parts of cooling system engine side 19-6 . Coolant hose connection diagram 19-12 . Draining and filling with coolant 18 . Page Page Page Page 19-

Coolant mixture ratios Page 19-18 , draining and filling with coolant.

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Cooling system components, removing and installing

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Cooling system components (body side)


1 - Radiator Removing and installing Page 19-25 After replacing replace entire coolant 2 - O-ring Replace if damaged 3 - Upper coolant hose Secured to radiator with retaining clip Check securely seated Coolant hose connection diagram Page 1912 4 - Air ducting

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Cooling system components, removing and installing

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5 - 10 Nm 6 - Additional fan Only vehicles with optional equipment

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7 - Fan ring 8 - Retaining clip Check seated securely 9 - Connector 10 - Coolant fan 11 - Bracket For radiator fan connector 12 - Lower coolant hose Secured to radiator with retaining clip Check securely seated Coolant hose connection diagram Page 1912 13 - O-ring Replace

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Cooling system components, removing and installing

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14 - Coolant Fan Control (FC) thermo switch F18-, 35 Nm For electric fan Switching temperatures: Stage 1 on: 92 to 97 C; off: 84 to 91 C Stage 2 on: 99 to 105 C; off: 91 to 98 C 15 - Bracket For radiator Note installed position 16 - 15 Nm

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Cooling system components, removing and installing

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Cooling system components (engine side)


1 - 15 Nm 2 - Toothed belt Mark direction of rotation before removing Check for wear Do not kink Removing, installing and tensioning Page 15-6 3 - Coolant pump Check for ease of movement If damaged or leaking replace complete Removing and installing Page 19-28

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4 - O-ring Replace

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Cooling system components, removing and installing

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5 - Coolant thermostat Checking: heat-up thermostat in water Opening commences approx. 87 C Ends approx. 102 C Opening lift min. 7 mm 6 - O-ring Replace 7 - Connection 8 - To heat exchanger Coolant hose connection diagram Page 1912 9 - O-ring Replace 10 - Connector 4 pin

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Cooling system components, removing and installing

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11 Engine - Coolant Temperature (ECT) sensor G62With Engine coolant temperature (ECT) gauge sensor -G2For engine control module If necessary release pressure in cooling system before removing Checking: Repair Manual , 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition, Repair Group 01 DTC memory; DTC memory, checking and erasing 12 - Retaining clip Check seated securely

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13 - Upper coolant hose Secured to radiator with retaining clip Check securely seated Coolant hose connection diagram Page 1912 14 - Lower coolant hose Secured to radiator with retaining clip Check securely seated Coolant hose connection diagram Page 1912

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15 - Oil cooler Removing and installing Page 17-11 , item 22 16 - From heat exchanger Coolant hose connection diagram Page 1912 17 - Lower coolant pipe Coolant hose connection diagram Page 1912 18 - 10 Nm 19 - Cap Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/9 Test pressure 1.4 to 1.6 bar

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20 - Seal Replace if damaged 21 - 10 Nm

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Cooling system components, removing and installing

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22 - Expansion tank Carry out leak test of cooling system with cooling system tester V.A.G 1274 and adapter V.A.G1274/8 23 To - turbocharger Coolant hose connection diagram Page 1912 24 - 15 Nm 25 - To upper coolant hose Only engine code AWP with automatic transmission Coolant hose connection diagram Page 1912 26 - After-Run coolant pump V51Only engine code AWP

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with automatic transmission Coolant hose connection diagram Page 1912 Checking Page 19-34

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27 From - turbocharger Only engine code AWP with automatic transmission Coolant hose connection diagram Page 1912

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Cooling system components, removing and installing

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Coolant hose connection diagram


Only vehicles with engine code AWD Vehicles with engine code AWP (manual transmission), AWW (manual and automatic transmission) Page 19-14 Vehicles with engine code AWP (automatic transmission) Page 19-16 1 - Radiator 2 - Oil cooler 3 - Coolant thermostat housing 4 Cylinder - head/cylinder block 5 - Expansion tank 6 Turbocharger -

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Cooling system components, removing and installing

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7 - Heating system heat exchanger 8 - Connection 9 Transmission - oil cooler Only with automatic transmission 10 - Lower coolant pipe 11 - Intake manifold 12 - Drain plug

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Cooling system components, removing and installing

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Vehicles with engine code AWP (manual transmission), AWW (manual and automatic transmission) 1 - Expansion tank 2 Turbocharger 3 - Intake manifold 4 Cylinder - head/cylinder block 5 - Connection 6 - Heating system heat exchanger 7 - Lower coolant pipe 8 Transmission - oil cooler Only engine code AWW with automatic transmission 9 - Upper coolant hose 10 - Drain plug 11 - Radiator 12 - Lower coolant

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Cooling system components, removing and installing

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hose

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Cooling system components, removing and installing

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13 - Oil cooler 14 - Coolant thermostat housing 15 - Coolant pump 16 - Coolant pipe

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Cooling system components, removing and installing

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Vehicles with engine code AWP (automatic transmission) 1 - Expansion tank 2 Turbocharger 3 - Intake manifold 4 Cylinder - head/cylinder block 5 - Coolant pipe 6 - Connection 7 - Heating system heat exchanger 8 Transmission - oil cooler Only with automatic transmission 9 - Lower coolant pipe 10 - Oil cooler 11 - Upper coolant hose

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Cooling system components, removing and installing

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12 - Radiator 13 - Lower coolant hose 14 - After-Run coolant pump V5115 - Coolant thermostat housing 16 - Coolant pump

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Cooling system components, removing and installing

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Cooling system, draining and filling


Special tools and equipment T10007 Refractometer V.A.G 1306 Drip tray VAS 5024 Assembly tool for springtype clamps

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Cooling system components, removing and installing

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Draining WARNING! Steam can be released when removing the cap from the expansion tank. Cover cap with a cloth and open carefully. - Open cap on coolant expansion tank. - Remove insulation tray: Repair Manual , Body Exterior, Repair Group 50; Body-Front; Sound insulation (gas engine) - assembly overview. - To drain coolant from radiator remove drain plug -arrow-.

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- To drain coolant from engine also remove coolant hose from oil cooler arrow-. Note: Observe disposal regulations! Filling Note: Only use coolant additive G 12 in accordance with TL VW 774 D. Identification: colored red On no account must G 12 be mixed with other coolant additives! If the fluid in expansion tank is brown, G 12 has been mixed with other coolant. In this case the coolant must be changed. G 12 and coolant additives marked "In accordance with TL VW 774 D" prevent frost and corrosion damage, scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with frost and corrosion protection additives. Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.

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Protection against frost must be assured to about -25 C (in arctic climatic countries to about -35 C). The coolant concentration must not be redu by adding water even in warmer seasons an warmer countries. The anti-freeze ratio mus at least 40 %. If for climatic reasons a greater frost protect is required, the amount of G 12 can be increased, but only up to 60 % (frost protec to about -40 C), as otherwise frost protect is reduced again and cooling effectiveness also reduced. The T10007 refractometer is recommended determining frost protection density. If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reu old coolant. Recommended mixture ratios: Frost protection to -25 -35 C C Anti-freeze amount 40 % 50 % 2.5 ltr. G 121) 2.0 ltr. Wat 3.0 2.5

1)

The quantity of coolant can vary depending u the vehicle equipment.

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- Screw drain plug into radiator.

- Push coolant hose onto oil cooler connection and secure with a springtype clamp.

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Vehicles of model year

2001

- Fill with coolant up to max. mark on expansion tank.

Vehicles of model year 2002 - Slowly fill expansion tank to upper marking of shaded field with coolant.

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Continuation for all vehicles - Install expansion tank cap. - Switch off heater and air conditioner. - Start engine and maintain an engine speed of about 2000 RPM for approx. 3 minutes. - Run engine until coolant fan starts. WARNING! Steam can be released when removing the cap from the expansion tank. Cover cap with a cloth and open carefully. - Check coolant level and top-up if necessary. Vehicles of model year 2001

When engine is at normal operating temperature, coolant level must be on the max. mark. When engine is cold, between min. and max. marks. Vehicles of model year 2002 When engine is at normal operating temperature, coolant level must be at upper marking of shaded field. When engine is cold, coolant level should be at approximately middle of shaded field.

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Cooling system components, removing and installing

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Radiator, removing and installing


Special tools and equipment T10007 Refractometer V.A.G 1306 Drip tray V.A.G 1331 Torque wrench (5 to 50 Nm) VAS 5024 Assembly tool for springtype clamps

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Removing - Drain coolant Page 19-18 .

- Remove front bumper: Repair Manual , Body Exterior, Repair Group 63; Front bumper, removing and installing front bumper - Remove coolant hoses from radiator. - Disconnect connector of thermo-switch. - Bring lock carrier into service position: Repair Manual , Body Exterior, Repair Group 50; Body, front; Lock carrier service position - Remove radiator securing bolts and take radiator with fan out downward. Note: Vehicles with air conditioner: - Observe additional information and removal work Page 19-27 . Installing Installation is carried out in the reverse order. Note the following: Filling with new coolant Page 19-18 .

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Cooling system components, removing and installing

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Additional information and removal work on vehicles with air conditioner CAUTION! The air conditioner refrigerant circuit must not be opened. Note: To prevent damage to condenser also to the refrigerant lines/hoses, make sure that the lines and hoses are not stretched, kinked or bent. - Remove retaining clamp(s) from refrigerant lines. - Remove condenser from radiator and secure to lock carrier.

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Cooling system components, removing and installing

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Coolant pump, removing and installing


Special tools and equipment T10007 Refractometer V.A.G 1306 Drip tray V.A.G 1331 Torque wrench (5 to 50 Nm) VAS 5024 Assembly tool for springtype clamps

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Note: Always replace seals and gaskets. The lower part of the toothed belt guard nee not be removed. The toothed belt should be left in position on the crankshaft sprocket. Cover toothed belt with a cloth to protect it f coolant before removing coolant pump. Removing - Drain coolant Page 19-18 . Page 13-10 .

- Remove ribbed belt

- Remove upper and center parts of toothed b guard Page 15-6 , Removing, installing an tensioning toothed belt. - Take toothed belt off coolant pump toothed b sprocket Page 15-6 , Removing, installing tensioning toothed belt. - Unscrew coolant pump securing bolts -1- an remove coolant pump -2-.

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Installing Installation is carried out in the reverse order. Note the following: - Moisten new O ring with coolant. - Insert coolant pump into cylinder block and tighten securing bolts. Tightening torque: 15 Nm Note: The coolant pump plug faces downward. - Install toothed belt and adjusting timing 15-6 . - Install ribbed belt Page 13-10 . Page 19-18 . Page

Filling with new coolant

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Cooling system components, removing and installing

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Thermostat, removing and installing


Special tools and equipment T10007 Refractometer V.A.G 1306 Drip tray V.A.G 1331 Torque wrench (5 to 50 Nm) VAS 5024 Assembly tool for springtype clamps

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Removing Note: Always replace seals and gaskets. - Drain coolant Page 19-18

- Pull coolant hose off connecting flange -3-. - Unbolt securing bolts -4- of connecting flange -3- and remove connecting flange -3- with thermostat -1-. Installing Installation is carried out in the reverse order. Note the following: - Moisten new O ring -2- with coolant. - Insert thermostat -1- into connecting flange -3- and turn 1/4 turn (90 ) to right. - Install connecting flange -3- with thermostat -1- into engine block.

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Note: The brace on the thermostat must be almost vertical. - Tighten securing bolts -4-. Tightening torque: 15 Nm Filling with new coolant Page 19-18 .

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Cooling system components, removing and installing

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After-run coolant pump, checking


Special tools and equipment VAG 1527B voltage tester

V.A.G 1594 A Auxiliary test set Wiring diagram

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Check conditions All fuses must be OK. Test sequence - Pull 2-pin connector off After-Run coolant pump -V51- -arrow- .

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- Connect contacts of After-Run coolant pump -V51- to battery using aux. cables from V.A.G 1594. Afterrun coolant pump must run. If the after-run coolant pump does not run: - Replace After-Run coolant pump V51-. If the After-Run coolant pump -V51runs: - Switch ignition off and on again. - Connect VAG 1527B voltage tester to disconnected connector for afterrun coolant pump (V51) with auxiliary cable from V.A.G 1594 A LED must light up. Note: This check must be performed within 5 minutes after switching ignition off. If the LED does not light up: - Locate and repair open circuit using wiring diagram: Electrical Wiring Diagrams, Troubleshooting & Component Locations

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