Cooling system components, removing and installing Page 1 of 38
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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Cooling system components, removing and installing Page 2 of 38
Removing and installing viscous fan Page
13-21 .
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Cooling system components, removing and installing Page 3 of 38
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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Cooling system components, removing and installing Page 4 of 38
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 cap
Testing pressure relief valve in filler cap
Page 19-33
11 -
Intake manifold
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Cooling system components, removing and installing Page 5 of 38
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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Cooling system components, removing and installing Page 6 of 38
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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Cooling system components, removing and installing Page 7 of 38
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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Cooling system components, removing and installing Page 8 of 38
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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Cooling system components, removing and installing Page 9 of 38
system must be filled all year round with the
correct anti-freeze and anti-corrosion additive.
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Cooling system components, removing and installing Page 10 of 38
19-8
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 anti-freeze ratio must
be at least 40 %.
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). Otherwise, frost
protection is reduced again and cooling
effectiveness is also reduced.
Only use clean drinking water for mixing the
coolant.
If radiator, heat exchanger, cylinder head or
cylinder head gasket is replaced, do not reuse
old coolant.
Use special tool T10007 to check frost
protection of coolant additive G012 A8 D in
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Cooling system components, removing and installing Page 11 of 38
cooling system.
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Cooling system components, removing and installing Page 12 of 38
19-9
Recommended mixture ratios:
Frost Anti-freeze G
Water1)
protection concentration 012A8
to
D 1)
40% 3.0 l 4.0 l
-25 C
50% 3.5 l 3.5 l
-35 C
1)
Coolant quantity: 7.0 liters (may vary
depending upon the vehicle equipment)
- Install lower coolant hose and secure.
- Screw adapter VAG 1274/8 onto coolant expansion tank.
- Fit special tool VAG 1274/10 onto adapter.
Note:
To fill expansion tank without special tools, remove expansion tank and
temporarily raise it about 100 mm.
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Cooling system components, removing and installing Page 13 of 38
19-10
- Remove seal from plenum chamber cover in direction of arrow.
- Remove plenum chamber cover -1- from front.
- Push back protective cover for coolant hose at connection of heat
exchanger.
- Release coolant hose to heat exchanger and pull back hose until
bleeder hole in coolant hose -arrow- is no longer covered by
connection.
- Top up coolant until it flows out at bleeder hole in coolant hose.
- Push coolant hose on connection and tighten.
- Install expansion tank cap.
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Cooling system components, removing and installing Page 14 of 38
19-11
- Start engine and maintain an engine speed of
about 2000 rpm for approx. 3 minutes.
- Allow engine to run at idling speed until lower
hose on radiator becomes hot.
WARNING!
Hot steam can escape when opening the cap
on the expansion tank: Cover cap with a cloth
and open carefully.
- Check coolant level and top up if necessary. If
engine is warm, coolant level must be at max.
mark; if cold, between min. and max. marks.
- Stop engine.
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Cooling system components, removing and installing Page 15 of 38
19-12
Coolant pump, removing and installing
Special tools and equipment
Socket head fastener T10092
Pin T40011
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Cooling system components, removing and installing Page 16 of 38
19-13
Removing
Engine in vehicle.
Lock carrier must be in service position
Page 13-1 .
- Drain coolant Page 19-4 .
- Remove ribbed belt and tensioner for ribbed belt
Page 13-18 .
- Secure pulley for viscous fan with pin punch -1- and unfasten using
Allen key -2-.
- Remove viscous fan from mounting.
- Remove engine cover -arrows-.
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Cooling system components, removing and installing Page 17 of 38
19-14
- Mark direction of rotation of belt with chalk or felt
pen.
- Remove top and center toothed belt guard
Page 13-35 .
- Set crankshaft to markings for TDC of No. 1 cylinder by turning central
bolt on crankshaft sprocket in direction of rotation -arrows-.
- Thread socket head fastener T10092 into tensioner for toothed belt.
Note:
Only tension pressure piston of tensioner until the piston is secured with
pin T40011.
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Cooling system components, removing and installing Page 18 of 38
19-15
- Take toothed belt off camshaft sprocket and
coolant pump.
Note:
The vibration damper and lower toothed belt
guard do not have to be removed.
The toothed belt should be left in position on
the crankshaft sprocket.
Before removing the coolant pump, cover
toothed belt with a cloth to protect from coolant.
- Remove coolant pump securing bolts -1- and remove coolant pump -2-.
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Cooling system components, removing and installing Page 19 of 38
19-16
Installing
Installation is carried out in the reverse order of
removal; note the following:
Note:
Always replace seals and gaskets.
- Clean and smooth down sealing surface for O-
ring as required.
- Lightly coat new O-ring -3- with coolant G 012 A8 D.
- Install coolant pump -2-.
Installation position: Sealing plug in housing faces downward.
- Tighten bolts -1- of coolant pump to 15 Nm.
- Install toothed belt (adjust valve timing) Page 13-44 .
Note:
Observe all instructions on removing and installing the toothed belt
Page 13-40 .
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Cooling system components, removing and installing Page 20 of 38
19-17
- Install ribbed belt and tensioner for ribbed belt
Page 13-20 .
- Install viscous fan Page 13-21 .
- Install lock carrier Page 13-1 .
- Top up coolant Page 19-7 .
Tightening torque
Component Nm
Coolant pump to cylinder block 15
Center section of toothed belt guard to
cylinder block
10
1)
Hose clamps for coolant hoses 2
1)
Install with locking fluid D 000 600 A2
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Cooling system components, removing and installing Page 21 of 38
19-18
Coolant thermostat, removing and
installing, checking
Removing
- Observe or obtain radio code on vehicles with
coded radio.
- Disconnect Ground strap at battery with ignition
switched off.
- Drain coolant Page 19-4 .
- Remove air duct hose -1-.
Note:
Connector -2- remains plugged in.
- Loosen ribbed belt by turning tensioner in direction of arrow.
- Remove ribbed belt from Generator pulley.
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19-19
- Secure pulley for viscous fan with pin punch -1- and unfasten using
Allen key -2-.
- Remove viscous fan from mounting and place in front of radiator cowl.
- Disconnect wiring from rear of Generator.
- Loosen connections for Generator from top and bottom and remove
Generator.
- Remove intake line support -arrows-.
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19-20
- Release clip and disconnect coolant hose from connection -2-.
- Remove bolts -1- remove connection, O-Ring -3- and coolant
thermostat -4-.
Installing
Installation is carried out in the reverse order of removal; note the
following:
Note:
Always replace seals and gaskets.
- Clean and smooth down sealing surface for O-ring as required.
- Lightly coat new O-ring with coolant G 012 A8 D.
- Insert coolant thermostat.
Installation position: Cross-piece on thermostat should be vertical.
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Cooling system components, removing and installing Page 24 of 38
19-21
- Install viscous fan Page 13-21 .
- Install ribbed belt and tensioner for ribbed belt
Page 13-20 .
- After connecting battery, enter anti-theft code for
radio.
Radio operating instructions
- Close windows fully using power window
switches.
- Actuate all power window switches again for at
least one second in the "close" direction to
activate automatic open/close function.
- Set clock to correct time.
- Top up coolant Page 19-7 .
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Cooling system components, removing and installing Page 25 of 38
19-22
Tightening torques
Component Nm
Connection to cylinder block 15
Support for intake manifold
to intake manifold 20
to bracket 20
Generator at bracket
M8 23
M10 46
Hose clamps for air duct hoses
3.5
Check coolant thermostat
- Heat thermostat in water bath.
Starts to Fully open Opening
open travel
at least 8 mm
approx. 87 C approx. 102 C
1)
1)
cannot be tested
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Cooling system components, removing and installing Page 26 of 38
19-23
Lower coolant line, removing and
installing
Special tools and equipment
VAG 1921
Removing
- Drain coolant Page 19-4 .
- Disconnect coolant hoses -1- and -3-.
- Unbolt coolant expansion tank -2- (-arrows-).
- Disconnect electrical wiring to coolant level display switch -F66- on
underside of expansion tank.
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19-24
- Remove air duct hose -1-.
Note:
Connector -2- remains plugged in.
- Disconnect heater hose at rear of coolant line -2-. To do this, release
retaining clip on connecting flange.
- Pull off coolant hose to oil cooler -4- at coolant line.
- Remove bolt -3-.
- Push lower coolant line toward rear of vehicle and remove.
- Remove plug -5- if necessary.
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19-25
Installing
Installation is carried out in the reverse order of
removal; note the following:
Note:
Always replace seals and gaskets.
- Before installing, clean and smooth down
sealing surface for O-ring.
- Moisten new O-ring -1- with G 012 A8 D coolant and slide onto coolant
line -2-.
- Push coolant line into opening in cylinder block.
- Top up coolant Page 19-7 .
Tightening torques
Component Nm
Coolant line to oil filter bracket 20
Hose clamps for coolant hoses
2
Hose clamps for air duct hoses
3.5
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19-26
Radiator, removing and installing
Special tools and equipment
VAG 1306
Removing
- Remove front bumper:
Repair Manual, Body Exterior, Repair Group 63
- Remove air cowl in front of charge air cooler -arrows-.
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19-27
- Disconnect cooling lines for power steering hydraulic fluid -arrows-.
WARNING!
Hot steam can escape when opening the cap on the expansion tank:
Cover cap with a cloth and open carefully.
- Open cover of coolant expansion tank
- Place drip tray VAG 1306 below engine.
- Turn drain screw -arrow- on radiator counter-clockwise. If necessary,
install a drain hose on connection.
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19-28
- Release coolant hose retaining clip -arrow- and remove coolant hose
from radiator.
- Disconnect coolant hose from top of radiator -arrow-.
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19-29
Vehicles with automatic transmission:
- Remove bolts -arrows-.
- Remove air duct -1- and -2-.
Note:
Observe cleanliness rules when working on the automatic transmission:
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
- Place drip tray underneath to collect oil.
- Remove ATF lines/hoses from radiator:
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
- Tie ATF lines to longitudinal member to avoid leakage of fluids.
All models:
CAUTION!
The air conditioner refrigerant circuit must not be opened.
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Cooling system components, removing and installing Page 33 of 38
19-30
Note:
To prevent damage to the condenser and
refrigerant lines/hoses, ensure that the lines and
hoses are not stretched, kinked or bent.
- Remove air cowls from radiator -4- (left and right).
- Remove securing bolts -1- and -2- for condenser.
- Disconnect connector -3- from air conditioner pressure switch -F129-.
- Pull condenser up out of its bracket, pivot toward side and secure to
right-hand front wheel with wire.
Note:
Protect fender panel from damage.
- Release two retaining pins for radiator and pull out upward -arrows-.
- Pivot radiator toward front and lift out.
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Cooling system components, removing and installing Page 34 of 38
19-31
Installing
Installation is carried out in the reverse order of
removal; note the following:
- Install front bumper:
Repair Manual, Body Exterior, Repair Group
63
- Top up coolant Page 19-7 .
Vehicles with automatic transmission:
- Attach ATF lines.
Repair Manual, 5 Spd. Automatic
Transmission 01V, Repair Group 37
- Check ATF level:
Repair Manual, 5 Spd. Automatic
Transmission 01V, Repair Group 37
Tightening torques
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Cooling system components, removing and installing Page 35 of 38
Component Nm
Condenser to radiator 10
Cooling lines to radiator 10
Hose clamps for coolant hoses 2
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19-32
Cooling system, checking for leaks
Special tools and equipment
VAG 1274
Adapter 1274/8
Adapter 1274/9
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Cooling system components, removing and installing Page 37 of 38
19-33
Test requirements:
Engine at operating temperature.
WARNING!
Hot steam can escape when opening the cap
on the expansion tank: Cover cap with a cloth
and open carefully.
- Open cover of coolant expansion tank
- Install tester VAG 1274 with adapter VAG 1274/8 onto expansion tank.
- Using hand pump on tester, build up a pressure of approx. 1.0 bar.
- If this pressure is not maintained, locate and repair leaks.
Testing pressure relief valve in filler cap
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Cooling system components, removing and installing Page 38 of 38
- Install tester VAG 1274 with adapter VAG 1274/9 onto sealing cover.
- Operate hand pump.
Pressure relief valve must open at a pressure of 1.4 to 1.6 bar.
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