Professional Documents
Culture Documents
4-cylinder injection engine (2.0 l direct injection engine, turbocharger) - Edition 02.2011
19 – Cooling
1 Cooling system
General notes on cooling system ⇒ page 132 .
n AG. Volkswagen A age G do
lksw es n
1.1 General notes eon
d b cooling system
yV
o ot g
ua
ran
ris tee
utho or
a ac
WARNING ss
ce
le
un
pt
an
Steam may escape when expansion tank is opened. Wear eye
d
itte
y li
protection and protective clothing to avoid eye injuries and
erm
ab
scalding. Cover cap with cloth and open carefully.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Caution
t to the co
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
rrectne
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
ss
vated charcoal filter system, coolant and refrigerant, brake
o
cial p
f i
fluid and vacuum) and electrical wiring in their original po‐
nform
sitions.
mer
atio
m
n
c
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
♦ When the engine is warm, the cooling system is under pres‐
cop Vo
by lksw
cted
sure. If necessary, release pressure before beginning repair
agen
Prote AG.
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ Spring-type clip pliers -VAS 6340- or hose clip pliers -VAS
6362- are recommended for installation of 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).
♦ The arrows on the coolant pipes and coolant hoses must be
aligned with each other.
♦ Only demineralised / distilled water to standard VDE-0510
may be used for mixing. Tap water does not have the required
quality to ensure the coolant's function.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
Special tools and workshop
ility
ot
equipment required
wit
, is n
h re
hole
♦ Refractometer -T10007-
spec
es, in part or in w
t to the co
-VAS 6208-
♦ Hose clip pliers -VAS 6340-
rrectness of i
♦ Cooling system charge unit
l purpos
-VAS 6096-
♦ Adapter for cooling system
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Procedure:
Draining
WARNING
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Filling
Note
pt
du
an
itte
y li
ab
wit
, is n
h re
spec
es, in part or in w
VDE
05101)
l purpos
orm
m
n in
c
Procedure:
or
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
Test prerequisite
• Engine at normal operating temperature
ss o
Test sequence:
cial p
f inform
mer
atio
WARNING
om
n
c
i
or
n
Hot steam may escape when expansion tank is opened. Place
thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Open filler cap on coolant expansion tank. C py
t. rig
gh ht
yri
– Screw adapter for cooling system tester -V.A.G 1274/8- into
p by
co Vo
by lksw
coolant expansion tank. Prote
cted AG.
agen
DANGER!
If pressure drops:
– Find leaks and rectify.
Checking pressure relief valve in filler cap:
– Screw cap into adapter for cooling system tester -V.A.G
1274/9- .
– Clamp connector -V.A.G 1274 B/1- into adapter for cooling
system tester -V.A.G 1274/9- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2.1 Coolant hose schematic diagram for vehicles with heat exchanger
ce
e
nl
pt
du
an
ing.
itte
y li
erm
ab
♦ Removing and installing
ility
ot p
⇒ page 152 .
wit
, is n
h re
7 - Engine oil cooler
hole
spec
es, in part or in w
8 - Turbocharger
t to the co
9 - Cylinder head
10 - Thermostat
rrectness of i
11 - Coolant pump
l purpos
12 - Expansion tank
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.2 Coolant hose schematic diagram for vehicles with 2nd heat exchanger
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
1 - Coolant hose
pt
an
d
itte
y li
❑ To expansion tank.
erm
ab
ility
ot p
2 - Coolant hose
wit
is n
❑ To heat exchanger
h re
❑ Return line ole,
spec
urposes, in part or in wh
t to the co
3 - Coolant hose
❑ To heat exchanger
❑ Supply
rrectne
4 - Coolant pipe
ss
5 - Coolant hose
o
cial p
f in
❑ From coolant pipe to
form
mer
supplementary water
atio
pump
om
n
c
i
or
n
6 - O-ring
thi
te
sd
va
7 - Coolant hose
i
o
pr
cum
r
fo
en
ng
19 - Coolant pipe
20 - Bracket for continued coolant circulation pump -V51- .
21 - Coolant pipe
❑ Return line
22 - Seal
23 - Coolant pipe
❑ Supply
24 - Coolant hose
25 - Coolant hose
❑ To expansion tank
n AG. Volkswagen AG do
swage es n
♦ Hose clip pliers -V.A.G by V1921-
olk ot g
ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Note
Note
olkswagen AG
en AG. V
♦ Hose unions and air intake pipes/hoses must be free of oiloland
ksw
ag does
not
grease when installing. db
yV gu
ara
rise nte
♦ Secure all hose connections with hose clips corresponding
au
tho to eo
ra
the series equipment ⇒ Electronic parts catalogue
ss . c
ce
e
nl
pt
du
an
the screws of the used hose clips have to be sprayed with
itte
y li
erm
ab
penetrating spray before installing.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
❑ Renew.
an
d
itte
y li
rm
3 - Connection
ab
pe
ility
ot
4 - Retaining clip
wit
, is n
h re
❑ Only for inserted ver‐
hole
spec
sion.
es, in part or in w
t to the co
ing.
5 - Coolant temperature send‐
rrectness of i
er -G62-
l purpos
nform
ercia
6 - O-ring
m
❑ Renew.
a
com
tion in
7 - Coolant pump
r
te o
thi
❑ Removing and installing
s
iva
do
⇒ page 149 .
r
rp
cum
fo
t.
yi Co
move protective cap . Cop py
rig
ht ht
rig
8 - Seal py by
co Vo
by lksw
❑ Renew. cted agen
Prote AG.
9 - Centralising pin
❑ Qty. 2.
10 - Toothed belt
❑ For coolant pump.
❑ Removing and installing
⇒ page 146 .
11 - Toothed belt guard
12 - Bolt
❑ 9 Nm
13 - Bolt
❑ Left-hand thread.
❑ Renew.
❑ 10 Nm + 90° further
14 - Toothed belt drive sprocket
❑ Note installation position.
15 - Oil seal
❑ Renewing ⇒ page 148 .
16 - Balancer shaft
17 - Thermostat
❑ Removing and installing ⇒ page 151 .
18 - Centralising pin
19 - O-ring
❑ Renew.
AG. Volkswagen AG d
20 - Connection agen oes
olksw not
V gu
by ara
21 - Bolt rised
nte
ho eo
❑ 9 Nm s aut ra
c
s
ce
e
nl
pt
du
an
itte
y li
Coolant pump - tightening sequence
erm
ab
ility
ot p
wit
Nm.
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
3.4 Removing and installing coolant temper‐
m
atio
om
n in
or c
thi
te
sd
a
Removing
iv
o
r
rp
cu
o
m
• Engine cold
f
en
ng
t.
yi Co
op
– Release clip -3- from pressure hose -4-. C py
t. rig
gh ht
yri by
– Release hose clip -arrow- from throttle valve module -J338- . op Vo
by c lksw
cted agen
Prote
– Unscrew bolt -1- from pressure pipe -2- and remove pressure
AG.
pipe -2-.
– Remove support for intake manifold (remove nut -2- and bolt
-1-).
– Disconnect electrical connector -1- at coolant temperature
sender -G62- .
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
♦ Renew O-rings.
h re
hole
spec
♦ Only demineralised / distilled water to standard VDE-0510
es, in part or in w
may be used for mixing. Tap water does not have the required
t to the co
quality to ensure the coolant's function.
♦ Insert new coolant temperature sender -G62- immediately into
rrectness of i
connection to avoid loss of coolant.
l purpos
♦ Hose unions and air intake pipes/hoses must be free of oil and
grease when installing.
nform
ercia
a
com
tion in
cum
fo
en
g
t.
yi Co
Cop py
t.
– Install throttle valve module -J338- ⇒ Rep. gr. 24 .
rig
gh ht
pyri by
Vo
o
by c
– Check coolant level ⇒ page 133 .
lksw
cted agen
Prote AG.
♦ Socket -T10360-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Removing
spec
es, in part or in w
t to the co
– Release long coolant pipe and lay aside ⇒ page 141 .
rrectness of i
– Disconnect coolant hoses -1 and 2- and move clear to one
side.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
– Unscrew bolts -arrows- and remove toothed belt guard.
lksw
cted agen
Prote AG.
Caution
ce
e
nl
pt
du
an
itte
Installing
y li
erm
ab
• Specified torque ⇒ page 144 .
ility
ot p
wit
, is n
Installation is carried out in the reverse order. When installing,
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Replace bolt for drive sprocket.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
for
en
ng
t.
yi
Special tools and workshop equipment required
Co
Cop py
t. rig
gh
♦ Thrust piece -T10353-
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Procedure
– Remove short coolant pipe ⇒ page 141 .
– Release long coolant pipe and lay aside ⇒ page 141 .
– Remove toothed belt for coolant pump ⇒ page 146 .
– Press screwdriver -1- firmly onto section -2- of oil seal
-arrow B-.
– Lever out oil seal -arrow A-.
– Clean contact surface and sealing surface.
ce
e
nl
pt
du
an
itte
y li
Risk of damage to thread.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Apply thrust piece -T10353- to oil seal -1- and press into cyl‐
t to the co
inder block as far as stop using bolt -2- (take care not to tilt oil
seal).
rrectness of i
– Fit toothed belt for coolant pump ⇒ page 146 .
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Remove bolts -1 … 5-.
erm
ab
ility
ot p
– Detach coolant pump from centring pin and pull off engine oil
wit
, is n
cooler.
h re
hole
spec
es, in part or in w
t to the co
Note
Ignore -arrow-.
rrectness of i
Installing
l purpos
nform
ercia
at
om
ion
c
in t
or
his
te
Note
a
do
priv
cum
for
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Coat O-rings -4- with coolant; coolants ⇒ Electronic parts cop Vo
by lksw
catalogue . cted agen
Prote AG.
– Check whether the two centring pins are fitted in the cylinder
block; install if necessary.
– Fit connecting piece -2- into engine oil cooler -1-.
– Push coolant pump -3- onto connecting piece and centring pin
into cylinder block.
Note
ce
e
pt
du
an
gine mounting.
itte
y li
erm
ab
– Remove engine mounting (left-side) ⇒ page 17 .
ility
ot p
wit
, is n
h re
et.
hole
spec
es, in part or in w
t to the co
– Unscrew bolts -arrows- and remove connection.
– Detach thermostat.
rrectness of i
Installing
l purpos
nform
ercia
at
om
ion
c
in t
or
his
e
Note
at
do
priv
cum
or
en
ng
t.
yi Co
Cop py
– Clean sealing surface for O-ring.
t. rig
gh ht
pyri by
Vo
o
by c
– Coat O-ring with coolant, Coolants ⇒ Electronic parts cata‐
lksw
cted agen
logue .
Prote AG.
9 - Expansion tank
pt
du
an
itte
ab
er -V.A.G 1274/8-
hole
spec
⇒ page 136 .
es, in part or in w
t to the co
10 - Bolt, 5 Nm
l purpos
or
12 - Bolt, 4 Nm
m
m
atio
m
13 - Breather line
o
n in
or c
thi
sd
iva
cu
o
m
f
en
ng
14 - Spring-type clip
t.
yi Co
op
❑ Hose clip pliers -VAS 6340- or hose clip pliers -VAS 6362- are recommended for installation of spring-
C py
t. rig
gh
type clips.
ht
pyri by
Vo
co lksw
by
cted
15 - Bolt, 1.2 Nm
agen
Prote AG.
16 - Retainer
❑ For continued coolant circulation pump -V51-
17 - Bolt, 4.5 Nm
18 - Continued coolant circulation pump -V51-
19 - Coolant hose
❑ Coolant hose schematic diagram ⇒ page 139 .
20 - Retainer
21 - Radiator outlet coolant temperature sender -G83-
❑ Coolant hose schematic diagram ⇒ page 139 .
22 - Retainer
23 - Spring-type clip
❑ Hose clip pliers -VAS 6362- are recommended to install spring-type clips.
24 - Radiator lower mounting
1 - Radiator
2 - Radiator fan -V7-
3 - Bolt, 5 Nm
4 - Bolt, 5 Nm
5 - Locking lug
❑ Must be engaged in ra‐ n AG. Volkswagen AG do
diator. lkswage es n
o ot g
byV ua
d
6 - Cowling o
ir se
ran
tee
th or
❑ Removing and installing
au ac
ss
⇒ page 154 .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.