Cooling system components Page 1 / 33

19 - 1

Cooling system components

Caution!

When doing any repair work, especially in the engine

compartment, pay attention to the following due to
clearance issues:

„ Route lines of all types (e.g. for fuel, hydraulic,

EVAP canister system, coolant and refrigerant,
brake fluid, vacuum) and electrical wiring so that
the original path is followed.

„ To prevent damage to the lines, make sure there

is 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.

„ Secure all hose connections with hose clamps,

allocation Electronic Parts Catalog "ETKA" .

„ Hose clamp pliers V.A.G 1921 or pliers for spring

clamps VAS 5024 A are recommended for installing
spring clamps.

„ Always replace gaskets and seals.

„ Arrows on coolant pipes and coolant hoses must line

up across from each other.

Cooling system components (on engine), assembly

overview 19-1, Cooling system components (on engine),
assembly overview .

Cooling system components (on body), assembly overview

19-1, Cooling system components (on body), assembly
overview .

Coolant hose connection diagram 19-1, Coolant hose

connection diagram
Cooling system components Page 2 / 33

Coolant, draining and refilling 19-1, Cooling system,

draining and filling

Coolant pump, removing and installing 19-1, Coolant

pump, removing and installing

Thermostat, removing and installing 19-1, Coolant

thermostat, removing and installing

Removing and installing Coolant Fan V7 and Coolant Fan

2 V177 19-1, Coolant Fan V7 and Coolant Fan 2 V177 ,
removing and installing

Radiator, removing and installing 19-1, Radiator,

removing and installing

Cooling system, checking for leaks 19-1, Cooling

system, checking for leaks

Cooling system components (on engine), assembly

overview

Part 1
Cooling system components Page 3 / 33

Part 2 Topic 19-1

„ Cylinder block

„ Oil cooler

„ 25 Nm

„ 10 Nm

„ To heater core of heater, bottom

„ Retaining clip

„ O-ring

„ Replace

„ Front coolant line

„ Connecting hose

„ O-ring

„ Replace

„ Coolant line

„ Connecting hose

„ Connecting piece

„ To radiator, bottom

„ 5 Nm

„ O-ring

„ Replace

„ Coolant thermostat

„ Removing and installing

19-1, Coolant thermostat,
removing and installing

„ Note installation position:

Valve must be at top

„ checking, coolant thermostat

installed:
Cooling system components Page 4 / 33

Vehicle Diagnosis, Testing

and Information System VAS
5051 "Guided functions"

„ Checking, coolant
thermostat removed:

Heat up thermostat in water

Starts to open: approx. 87 C

End of opening: approx. 102
C
Open distance: at least 7 mm

„ Seal

„ Replace

„ 25 Nm

„ Coolant thermostat housing

„ Seal

„ Replace

„ Bracket for assemblies

„ 10 Nm

„ Coolant pump

„ Removing and installing

19-1, Coolant pump,
removing and installing

„ O-ring

„ Replace

„ Right coolant line

„ Secured to engine mount

„ To expansion tank, bottom

Part 2
Cooling system components Page 5 / 33

Part 1 Topic 19-1

„ Pipe connection

„ Pressed in cylinder head

„ Clean before installing

coolant distribution housing
Item - 15 -

- If necessary, remove
coolant deposits using a
copper wire brush or fine
sandpaper (minimum 100
grit).

„ Circlip

„ Seal
Cooling system components Page 6 / 33

„ Replace after removing

coolant distribution housing
Item - 15 -

„ To expansion tank, top

„ Rear coolant pipe

„ 10 Nm

„ Heat shielding

„ To heater core, top

„ Supply hose

„ To ATF cooler

„ Only for vehicles with

automatic transmission

„ To lower heat exchanger

„ Return hose

„ Coolant line

„ Bolted to coolant regulator

housing Item - 15 -

„ To coolant regulator housing

„ Coolant distribution housing

„ Supply hose

„ To top of radiator

„ Throttle valve control module

J338

„ Coolant heated

„ Engine Coolant Temperature

(ECT) Sensor G62

„ O-ring

„ Replace

„ Retaining clip
Cooling system components Page 7 / 33

Cooling system components (on body), assembly

overview

„ Upper coolant hose

„ For coolant distribution

housing on cylinder head

„ O-ring

„ Replace if damaged

„ Radiator

„ Removing and installing

19-1, Radiator, removing
and installing

„ After replacing replace entire

amount of coolant
Cooling system components Page 8 / 33

„ Gasket

„ Cap

„ Check using cooling system

tester V.A.G 1274 and
adapter V.A.G 1274/9
Topic 19-1 .

„ Pressure release valve must

open at a pressure of 1.4 to
1.6 bar.

„ Connector

„ 3 Nm

„ Expansion tank

„ Perform leak test of cooling

system using cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/8 19-
1, Cooling system, checking
for leaks .

„ Bracket

„ For radiator

„ 5 Nm

„ Spacer piece

„ For coolant line bracket

„ Support

„ Insert in lock carrier

„ 5 Nm

„ Air shroud

„ 5 Nm

„ Coolant Fan 2 V177

„ Removing and installing

19-1, Coolant Fan V7 and
Coolant Fan 2 V177 ,
Cooling system components Page 9 / 33

removing and installing

„ Connector

„ Connector

„ Coolant Fan V7

„ Removing and installing

19-1, Coolant Fan V7 and
Coolant Fan 2 V177 ,
removing and installing

„ With Coolant Fan Control

(FC) Control Module J293

„ Lower coolant hose

„ From connection for coolant

regulator

„ Retaining clip

„ Engine Coolant Temperature

(ECT) Sensor (on Radiator) G83

„ O-ring

„ Replace

Coolant hose connection diagram

Cooling system components Page 10 / 33

„ Radiator

„ Removing and installing

19-1, Radiator, removing
and installing

„ Replace coolant after

replacing

„ Coolant line

„ Intake manifold

„ Coolant pump and coolant

thermostat

„ Coolant pump, removing and

installing 19-1, Coolant
pump, removing and
installing

„ Thermostat, removing and

Cooling system components Page 11 / 33

installing 19-1, Coolant

thermostat, removing and
installing

„ Checking coolant regulator

Item - 17 -

„ Front coolant line

„ Secured to bracket for

assemblies

„ Right coolant line

„ Secured to engine mount

„ Expansion tank

„ With sealing cap

„ Pressure relief valve in cap,

checking Topic 19-1

„ Rear coolant pipe

„ Cylinder head/cylinder block

„ Replace coolant after

replacing

„ Coolant distribution housing

„ Quick-release coupling

„ Lower connection

„ Heater core of heater

„ Replace coolant after

replacing

„ Quick-release coupling

„ Upper connection

„ ATF cooler

„ Only for vehicles with

automatic transmission
Cooling system components Page 12 / 33

„ Oil cooler

„ Throttle valve control module

J338

„ Quick-release coupling

„ Upper connection

„ Quick-release coupling

„ Lower connection

Cooling system, draining and filling

Special tools, testers and auxiliary items

required

„ Refractometer T10007
Cooling system components Page 13 / 33

„ Drip tray V.A.G 1306 or drip tray

for workshop crane VAS 6208

„ Spring-type clip pliers VAS 5024

A

„ Cooling system charge unit VAS

6096

„ Adapter V.A.G 1274/8

Draining

Note:

„ Drained coolant must be stored in a clean container

for disposal or reuse.

„ Follow disposal regulations.

Warning!

Hot steam may escape when opening expansion tank.

Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.

- Open cap of coolant expansion tank.

- Remove noise insulation

Repair Manual, Body Exterior, Repair Group 50,

- Place Drip tray V.A.G 1306 or drip tray for workshop

crane VAS 6208 underneath.
Cooling system components Page 14 / 33

- Open spring clamp - arrow - and disconnect coolant

hose.

If quick acting coupling at lower radiator connection is

pulled off, a large amount of coolant flows on to bumper.

Filling

Note:

„ Only coolant additive G 12 plus (according to TL VW

774 F) must be used. Distinguishing feature: colored
violet

„ G 12 plus (according to TL VW 774 F) may be mixed

with previous coolant additive G 12!

„ G 12 plus and coolant additives marked "in

accordance with TL VW 774 F" prevent frost and
corrosion damage, scaling and also raise the boiling
point of the 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.

„ Protection against frost must be assured to about -

25 C (in arctic climatic countries to about -35
C).

„ The coolant concentration must not be reduced by

adding water even in warmer seasons and in
warmer countries. The coolant additive portion must
be at least 40%.
Cooling system components Page 15 / 33

„ If for climatic reasons a greater frost protection is

required, the amount of G 12 plus can be increased,
but only up to 60% (frost protection to about -40
C), as otherwise frost protection is reduced again
and cooling effectiveness is also reduced.

„ If radiator, heat exchanger, cylinder head or cylinder

head gasket is replaced, do not reuse old coolant.

Recommended mixture ratios:

Frost protection to Anti-freeze portion G 12 1) Water 1)

-25 C 40% 3.6 l 5.4 l
-35 C 50% 4.5 l 4.5 l

1) The quantity of coolant can vary depending upon the

vehicle equipment.

- Connect coolant hose onto connection and secure using

spring-type clamp.

- Install noise insulation

Repair Manual, Body Exterior, Repair Group 50,

Fill using cooling system filler unit VAS 6096 .

- Thread adapter V.A.G 1274/8 on expansion tank.

- Fill coolant circuit using cooling system filling unit VAS

6096 Operating instructions for cooling system filler unit
VAS 6096 .

Filling without cooling system filler unit VAS 6096

Cooling system components Page 16 / 33

- Slowly fill coolant up to top marking of hatched area -

arrow - on expansion tank.

- Close expansion tank.

- Turn off heater and air conditioning.

Vehicles without auxiliary heater

- Start engine and maintain an engine speed of about 2000

rpm for approx. 3 minutes.

- Allow engine to run until Coolant Fan V7 starts running.

Vehicles with auxiliary heater

Caution!

Auxiliary heater should only be switched on if coolant

circuit is filled as described below.

- Connect vehicle diagnosis, testing and information

system VAS 5051 as follows:

- Connect diagnostic cable connector to Data Link

Connector (DLC) in drivers footwell.

- Start engine and maintain an engine speed of about 2000

rpm for approx. 3 minutes.
Cooling system components Page 17 / 33

- Press buttons for "Vehicle Self-Diagnosis" , "18 -

Auxiliary Heater" and "03 - Output Diagnostic Test Mode
(DTM)" on display in succession.

- Press right arrow button on display until you reach

Engine Coolant (EC) Switch-Off Valve (heater) N279
Output Diagnostic Test Mode (DTM).

- Conduct Engine Coolant (EC) Switch-Off Valve (heater)

N279 Output Diagnostic Test Mode (DTM). Continue to
maintain 2000 RPM (for approx. 1 min.).

- Allow engine to run until Coolant Fan V7 starts running.

Continuation for all vehicles

Warning!

Hot steam may escape when opening expansion tank.

Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.

- Check coolant level and top off as necessary.

„ With engine at operating temperature, coolant level

must lie at top marking of hatched area - arrow - .

„ With engine cold, coolant level should be located

approximately in center of hatched area.

Coolant pump, removing and installing

Cooling system components Page 18 / 33

Special tools, testers and auxiliary items

required

„ Engine support bridge 10-222 A

„ Adapter 10-222 A/3

„ Adapter 10-222 A/8

„ Shackle 10-222 A/12

„ Torque wrench V.A.G 1331

„ Torque wrench V.A.G 1332

Caution!
Cooling system components Page 19 / 33

When doing any repair work, especially in the engine

compartment, pay attention to the following due to
clearance issues:

„ Route lines of all types (e.g. for fuel, hydraulic,

EVAP canister system, coolant and refrigerant,
brake fluid, vacuum) and electrical wiring so that
the original path is followed.

„ To prevent damage to the lines, make sure there

is sufficient clearance to all moving or hot
components.

Removing

- Remove engine cover with air filter 24-1, Engine cover

with air filter, removing and installing .

- Remove battery

Repair Manual, Electrical Equipment, Repair Group 27,

- Open cover - 1 - of E-box and unscrew wire - 2 - .

- Remove bolts - arrows - and remove battery holder from

vehicle.

Warning!
Cooling system components Page 20 / 33

Hot steam may escape when opening expansion tank.

Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.

- Drain coolant 19-1, Cooling system, draining and

filling .

- Remove air guide on lock carrier - arrows - .

- Remove intake hose - 4 - . To do so, disconnect air

hoses - 1 - and - 2 - (compress securing ring) and
remove spring clamp - 3 - .

- Remove front and rear sections of right front wheel

housing liner

Repair Manual, Body Exterior, Repair Group 66,

- Remove ribbed belt for generator and coolant pump

13-1, Ribbed belt, removing and installing .
Cooling system components Page 21 / 33

- Remove 4 nuts - 2 - and bolts - 3 - .

- Pull off exhaust pipe - 1 - from manifold and tie up firmly

to side 26-1, Front exhaust pipe with catalytic converter,
removing and installing .

Note:

„ Flex joint in front exhaust pipe must not be bent

more than 10 , otherwise it may be damaged.

- Remove pendulum support

Repair Manual, Suspension, Wheels, Steering, Repair

Group 40,

Vehicles with manual transmission

- Remove shift mechanism from transmission

Repair Manual, 5 Spd. Manual Transmission 0A4,

Repair Group 34,

Vehicles with automatic transmission

- Remove selector lever cable from transmission

Repair Manual, 6 Spd. Automatic Transmission 09G,

Repair Group 37,

.
Cooling system components Page 22 / 33

- Remove selector lever cable from transmission

Repair Manual, Automatic Transmission 09G, Repair

Group 37,

Continuation for all vehicles

- Install engine support bridge 10-222A with adapters 10-

222A/8 and support engine/transmission assembly in
installation position using adapter 10-222A/3 and shackle
10-222 A/12 .

Note:

„ Illustration shows the arrangement with automatic

transmission.

„ In vehicles with manual transmission, spindle - A -

is to be located toward rear and secured to
reinforcement brace of transmission.

- Remove bolt - 2 - and place windshield washer reservoir

- 1 - toward front.
Cooling system components Page 23 / 33

- Remove bolts - 6 - and disconnect connector - 3 - .

- Remove bolts - 5 - and set down coolant expansion tank

with connected hoses on to engine.

- Remove bolts - 1 - , - 2 - and - 3 - and remove engine

mount.

The rear bolt in cylinder block is accessible above wheel

housing liner.

- Remove transmission-side subframe bracket bolts -

arrows - .

- Slide engine as far as possible toward front and toward

left.
Cooling system components Page 24 / 33

- Remove 3 mounting bolts Item - 23 - and swivel

coolant pump - A - out as depicted.

Installing

Installation is in reverse order of removal. Note the

following:

„ Replace O-ring for coolant pump.

„ Note installation position of coolant pump. Sealing

plug in housing points downward.

„ Fill with coolant 19-1, Cooling system, draining

and filling .

„ Install battery

Repair Manual, Electrical Equipment, Repair Group 27,

Tightening torques:

Component Nm
Install subframe mount 10-1, Assembly mounting
Coolant pump to cylinder block 10

Coolant thermostat, removing and installing

Note:

„ Checking coolant regulator Item - 17 - .

Cooling system components Page 25 / 33

Special tools, testers and auxiliary items

required

„ Refractometer T10007

„ Drip tray V.A.G 1306 or drip tray

for workshop crane VAS 6208

„ Torque wrench V.A.G 1331

„ Spring-type clip pliers VAS 5024

A

Removing

Warning!

Hot steam may escape when opening expansion tank.

Cooling system components Page 26 / 33

Wear protective goggles and protective clothing to

prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.

- Drain coolant 19-1, Cooling system, draining and

filling .

- Remove engine cover with air filter 24-1, Engine cover

with air filter, removing and installing .

- Remove intake manifold 24-1, Intake manifold,

removing and installing .

- Insert guide tube for oil dipstick into cylinder block again
and screw it tightly so that no escaping coolant can run into
engine.

- Place a suitable container under coolant regulator

housing to catch coolant flowing out.

- Remove bolts - arrows - , disconnect connection - A -

and remove coolant regulator.

Installing

Installation is in reverse order of removal. Note the

following:

„ Replace sealing ring Item - 18 - and O-ring

Item - 16 - .
Cooling system components Page 27 / 33

„ Note installation position of coolant regulator - 1 - .

Valve - 2 - must point upward.

„ Fill with coolant 19-1, Cooling system, draining

and filling .

Tightening torque:

Component Nm
Connection to coolant regulator housing 5

Coolant Fan V7 and Coolant Fan 2 V177 , removing and

installing

Removing

- Remove noise insulation

Repair Manual, Body Exterior, Repair Group 50,

- Unclip lower coolant hose from intake air elbow.

Cooling system components Page 28 / 33

- Disconnect electrical harness connector - 1 - and

remove mounting bolts of intake air elbow - arrows - .

- Remove air intake elbow downward.

- Disconnect electrical harness connector - 1 - and lay

cable free. Installation position of harness connector
deviates from illustration.

- Remove nuts - arrows - and remove fans.

Installing

Installation is in reverse order of removal. Note the

following:

Tightening torques:

Component Nm
Coolant fan to intake air elbow 5
Intake air elbow to radiator 5

Radiator, removing and installing

Cooling system components Page 29 / 33

Special tools, testers and auxiliary items

required

„ Refractometer T10007

„ Drip tray V.A.G 1306 or drip tray

for workshop crane VAS 6208

„ Spring-type clip pliers VAS 5024

A

„ Cooling system charge unit VAS

6096

„ Adapter V.A.G 1274/8

Removing
Cooling system components Page 30 / 33

Warning!

Hot steam may escape when opening expansion tank.

Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.

- Drain coolant 19-1, Cooling system, draining and

filling .

- Bring lock carrier into service position

Repair Manual, Body Exterior, Repair Group 50,

- Disconnect coolant connections on radiator at top and

bottom (quick acting couplings).

- Remove air intake elbow with coolant fans 19-1,

Coolant Fan V7 and Coolant Fan 2 V177 , removing and
installing .

- Remove bumper cover guide piece on left and right

Repair Manual, Body Exterior, Repair Group 63,

- Remove intake air connection on lock carrier - arrows -

.

Note:

„ To prevent damage to condenser and also to the

refrigerant lines/hoses, ensure that the lines and
hoses are not stretched, kinked or bent.
Cooling system components Page 31 / 33

- Remove bolts - 1 - from radiator bearings.

- Swing radiator slightly toward rear.

- Remove condenser mounting bolts - 2 - .

- Remove bolt - arrow - for mount of refrigerant line.

- Take radiator up and out.

Installing

Installation is in reverse order of removal. Note the

following:

„ Replace coolant if a new radiator was installed.

„ Fill with coolant 19-1, Cooling system, draining

and filling .

Tightening torques:

Component Nm
Radiator mounting to lock carrier 5
Condenser to radiator 5
Intake air elbow to radiator 5
Cooling system components Page 32 / 33

Cooling system, checking for leaks

Special tools, testers and auxiliary items

required

„ Cooling system tester V.A.G

1274

„ Adapter V.A.G 1274/8

„ Adapter V.A.G 1274/9

„ Engine at operating temperature

Test sequence:

Warning!
Cooling system components Page 33 / 33

Hot steam may escape when opening expansion tank.

Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.

- Open cap of coolant expansion tank.

- Position cooling system tester V.A.G 1274 with adapter

V.A.G 1274/8 on expansion tank.

- Generate a positive pressure of approx. 1.0 bar using

hand pump of tester.

If pressure drops:

- Search for leaking areas and repair malfunction.

Checking pressure relief valve in sealing cap

- Attach cooling system tester V.A.G 1274 with adapter

V.A.G 1274/9 on sealing cap.

- Operate hand pump.

„ Pressure release valve must open at a positive

pressure of 1.4 to 1.6 bar.