19-1

Parts of cooling system,

removing and installing
Note:

When the engine is warm, the cooling system is

under pressure. If necessary release pressure
before beginning repair work.

Hoses are secured with spring-type clips. In

cases of repair use spring-type clips.

VAG 1921 pliers are recommended when

installing spring-type clips.

Perform cooling system leakage check with

cooling system tester VAG 1274 and adapter
1274/3.

Parts of cooling system body side Page 19-2 .

Parts of cooling system engine side Page 19-

10 .

Coolant hose connection diagram Page 19-

14 .

Draining and filling with coolant Page 19-16 .

Coolant mixture ratios Page 19-16 , draining
and filling with coolant.

Checking thermo switch and coolant circulation

pump or continued coolant circulation pump
Page 19-27 .
 19-2

Parts of cooling system, body side

Vehicles 12.95

Vehicles 01.96 Page 19-6

1 - 10 Nm
2 - Lock carrier
3 - Radiator grille
4 - Air ducting
Secured at radiator:
Vertically 4 screws, horizontally 4 rivets or 4 screws -
arrows-
5 - Securing rubber
6 - Radiator
Removing and installing Page 19-22
After replacing, replace coolant
7 - Seal
Always replace
 19-3

8 - Coolant fan control (FC) thermal switch -F18-, 35

Nm
Switching temperatures:
1st speed on: 84 - 89 C
off: 76 - 83 C
2nd speed
on: 90 - 95 C
off: 82 - 89 C
9 - Radiator cowling
With electric fan and adjustable shut-off ring (only
vehicles with optional equipment)
10 - Cable clip
11 - Adjusting device
Only vehicles with optional equipment
Checking:
Engine cold (coolant temperature below 25 C) shut-
off ring item - 13 - closed
12 - Radiator fan
 19-4

13 - Shut-off ring
Only vehicles with optional equipment
14 - Cover
15 - Expansion tank
16 - To cylinder head
Coolant hose connection diagram Page 19-14
17 - To coolant line
Coolant hose connection diagram Page 19-14
18 - To heat exchanger
Only vehicles with optional equipment
19 - Junction piece
20 - Coolant breather hose
To top of radiator
 19-5

21 - Cap
Check with cooling system tester VAG 1274 and
adapter VAG 1274/4
Test pressure 1.3 - 1.5 bar
22 - Lower coolant hose
Coolant hose connection diagram Page 19-14
23 - Rubber washer
24 - Pin
25 - Upper coolant hose
Coolant hose connection diagram Page 19-14
26 - Spreader clip
27 - Bracket
 19-6

Vehicles 01.96

1 - 10 Nm
2 - Charge air cooler
3 - Coolant breather hose
4 - Upper coolant hose
Coolant hose connection diagram Page 19-14
5 - Radiator
Removing and installing Page 19-22
After replacing, replace coolant
6 - Lock carrier
 19-7

7 - Coolant fan control (FC) thermal switch -F18-, 35

Nm
Switching temperatures:
1st speed
on: 84 - 89 C
off: 76 - 83 C
2nd speed
on: 90 - 95 C
off: 82 - 89 C
8 - Connector
Black, 3 pin
For radiator fan thermo switch
9 - Adjusting device
Checking:
Engine cold (coolant temperature below 25 C) shut-
off ring item - 13 - closed
10 - Right coolant fan -V35-
Removing and installing Page 19-22
 19-8

11 - 2 pin connector
Black
For right coolant fan -V35-
12 - 2 pin connector
Black
For left coolant fan -V7-
13 - Shut-off ring
14 - Cable guide
15 - Left coolant fan -V7-
Removing and installing Page 19-22
 19-9

16 - Lower coolant hose

Coolant hose connection diagram Page 19-14
17 - Expansion tank
18 - To cylinder head
Coolant hose connection diagram Page 19-14
19 - To coolant line
20 - Junction piece
21 - Coolant breather hose
22 - Cap
Check with cooling system tester VAG 1274 and
adapter VAG 1274/4
Test pressure 1.3 - 1.5 bar
23 - Air intake ducting
24 - Securing rubber
 19-10

Parts of cooling system - engine side

1 - Toothed belt guard - lower part

01.95
2 - 20 Nm
3 - Toothed belt guard - upper part
4 - Camshaft sprocket securing bolt
Observe steel type marking on bolt head:
8.8 = 85 Nm
10.9 = 100 Nm
Counter-hold with 3036 to loosen and tighten
5 - Camshaft sprocket
Note position when installing toothed belt:
Vehicles 01.95 Page 13-34 , Removing, installing
and tensioning camshaft toothed belt;
Vehicles 02.95 Page 13-45 , Removing,
installing and tensioning camshaft toothed belt
 19-11

6 - Rear toothed belt guard

01.95
02.95 Page 13-12 , item 5
7 - Coolant pump
Check for ease of movement
Replace complete if damaged or leaking
01.95 with elongated holes:
To tension the toothed belt, loosen slightly and turn
using a screwdriver Page 13-34 , Removing,
installing and tensioning camshaft toothed belt
8 - O-Ring
If leaking and damaged replace
9 - Retaining clip
Check seated securely
 19-12

10 - Coolant circulation engine coolant temperature

(ECT) thermal switch -F51- or After-run coolant
thermal switch -F95-
Checking engine coolant temperature thermal switch
-F51- or after-run coolant thermal switch Page 19-
27
11 - Connection
12 - 10 Nm
13 - Coolant thermostat
Checking: heat-up thermostat in water
Opening commences approx. 87 C
Ends approx. 102 C
Opening lift min. 7 mm
 19-13

14 - Engine coolant temperature (ECT) sensor -G62-

With temperature gauge sensor -G2-
Engine code AAB
Checking:

Electrical Wiring Diagrams, Electrical Malfunction Finding

and Installing Locations Binder

15 - Camshaft toothed belt

Mark direction of rotation before removing
Check for wear
Do not kink
Removing, installing and tensioning: Vehicles
01.95 Page 13-34 ; Vehicles 02.95 Page 13-
45
 19-14

Coolant hose connection diagram

Vehicles with engine codes AAB, ACV

1 - Expansion tank
2 - Radiator
a = top
b = bottom
3 - Coolant pump -V50- or after-run coolant pump -
V51-
Checking Page 19-27
4 - Drain screw, 10 Nm
5 - Coolant thermostat
6 - Coolant pump
7 - Cylinder block
8 - Oil cooler
9 - Cylinder head
 19-15

10 - Solenoid valve
Only vehicles with optional equipment
11 - Additional heater
Only vehicles with optional equipment
12 - Control valve
Only vehicles with optional equipment
13 - Heating system heat exchanger
14 - Additional heat exchanger
Only vehicles with optional equipment
 19-16

Coolant, draining and filling

Special tools and equipment required

VAG 1306 Drip tray

VAG 1331 Torque wrench (5...50 Nm)
VAG 1921 Spring-type clip pliers
Anti-freeze tester
 19-17

Draining

- Remove cap from coolant expansion tank.

- Remove insulation tray:

Repair Manual , Body Exterior, Repair Group

50; Removing and installing lock carrier with
attachments

- Drain coolant:
Either via drain plug -1- and coolant hose -2-,
or via thermostat connection -3-.

If the cooling system was filled with G 11 anti-freeze -colored green-:

- Before reinstalling the coolant hose or flange and filling with new anti-freeze G
12 -colored red-, the cooling system must be flushed out.
- Remove as much of the coolant remains as is possible from the cooling system.
To do this e.g. blow compressed air into the coolant expansion tank.
- Close cooling system and top off with with pure water.
 19-18

- Run engine at idling speed for approx. 2

minutes.

- Drain off coolant and blow out the cooling

system again with compressed air.

Note:

Observe disposal regulations!

- Insert drain plug and tighten to 10 Nm.

Filling

Note:

When refilling the coolant system only use G

12.

The frost and corrosion protection additive G 11

must only be used for topping off purposes,
when the cooling system is still filled with G 11.

Identification: Green in color

On no account must G 12 be mixed with other

coolant additives!
WARNING!

On no account must the coolant additives -G

11- and -G 12- be mixed. If these additives are
mixed it will cause serious engine damage.
 19-19

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 (G 11) and coolant additives marked "In

accordance with TL VW 774 D (C)" prevent
frost and corrosion damage, scaling and also
raise 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 anti-freeze ratio must be
at least 40%.

If for climatic reasons a greater frost protection

is required, the amount of G 12 can be
increased, but only up to 60% (frost protection
to about -40 C), 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.
 19-20

Recommended mixture ratios:

Frost Anti-freeze G Water2)

protection to amount1) 112)
-25 C 40 % 3.6 5.4 ltr.
ltr.
-35 C 50 % 4.5 ltr.
4.5
ltr.

1)The amount of anti-freeze must not exceed

60%; frost protection and cooling effect will
decrease if amount of anti-freeze is too high.

2)The quantity of coolant can vary depending

upon the vehicle equipment.

- Open bleeder screw in coolant hose to heat

exchanger.

- Press down top radiator hose.

- Slowly fill with coolant up to max. mark on expansion tank (filling time approx. 5
minutes).
- Close bleeder screw.
- Start engine and run at approx. 1500 rpm for max. 2 minutes and at the same
time fill with coolant up to over-flow hole on expansion tank.
 19-21

- Install expansion tank cap.

- Run engine until radiator fan cuts-in.

- Check coolant level and top off if necessary.

When the engine is at normal operating
temperature, the coolant level must be on the
max. mark, when the engine is cold, between
the min. and max. marks.
 19-22

Radiator and fan, removing and installing

Special tools and equipment required

VAG 1306 Drip tray

VAG 1331 Torque wrench (5 - 50 Nm)
VAG 1921 Spring-type clip pliers
Anti-freeze tester
 19-23

Removing

- Removing insulation tray:

Repair Manual , Body Exterior, Repair Group

50; Body front

- Drain coolant Page 19-16

- Remove coolant hoses off radiator using hose

clip pliers VAG 1921.

- Disconnect connectors off engine coolant

temperature (ECT) thermal switch -F51- and
coolant fan.

Engine code ACV

- Remove charge air cooler bracket -1-.

- Remove charge air cooler with air hoses Page 21-7 , Removing and installing
parts of charge air cooling system.

Continued for all vehicles

- Removing radiator grille:

Repair Manual , Body Exterior, Repair Group 66; Trims

 19-24

Vehicles 10.91

- Disconnect power steering hydraulic line from

radiator.

Vehicles with air conditioner

Note:

Observe additional information and removal work

Page 19-26 .

- Remove retaining clamp -1- from refrigerant lines.

- Remove securing screws -2- on left and right of condenser.
- Lift condenser out of brackets and place on cross member.

Continued for all vehicles

- Unclip radiator/charge air cooler securing rubber from lock carrier.

- Remove lock carrier:

Repair Manual , Body Exterior, Repair Group 50; Removing and installing lock
carrier with its attachments
 19-25

Continued for all vehicles

- Lift out radiator with fan and air guide.

Installing

Installation is carried out in the reverse order,

when doing this note the following:

- Fill with coolant Page 19-16

Electrical connections and routing:

Repair Manual, Electrical Wiring Diagrams,

Troubleshooting & Component Locations

- Check headlight adjustment and adjust if

necessary:

Repair Manual, Maintenance

 19-26

Additional information and removal work on

vehicles with air conditioner

WARNING!

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.

- Unbolt condenser and secure to body so that

refrigerant lines/hoses are not stressed.
 19-27

Coolant circulation engine coolant temperature

(ECT) thermal switch -F51- or after-run coolant
thermal switch -F95-, checking

Special tools and equipment required

VAG 1526 Multimeter

VAG 1527 B LED voltage tester
VAG 1594 A Adapter set
Wiring diagram
 19-28

Test sequence

- Remove insulation tray:

Repair Manual , Body Exterior, Repair Group

50; Noise insulation assembly overview

- Disconnect 2-pin connector -2- off thermal switch for after-run coolant thermal
switch -F95- -1-.
- Bridge contacts 1 and 2 of connector -2- using auxiliary cables from VAG 1594
A.
Coolant circulation pump must start.

When coolant circulation pump does not run:

- Disconnect 2-pin connector from coolant pump -V50- or continued after-run

coolant pump -V51- -1- and connect LED voltage tester VAG 1527 with aux.
cables from VAG 1594 to disconnected connector.
The LED must flash or light up.

LED flashes or lights up (voltage supply OK.):

- Replace coolant pump -V50- or after-run coolant pump -V51-.
 19-29

If LED does not light up or flash:

- Locate and correct open circuit using wiring

diagrams:

Wiring diagrams, Electrical Troubleshooting

and Installing Locations Binder

Checking thermal switch resistance

- Connect multimeter VAG 1526 or multimeter VAG 1715 using cables from VAG
1594 to thermal switch -B- connector contacts -1- and -4- to measure resistance.
- Specifications:
below approx. 103 C=
above approx.: 104 C=0

If the specifications are not attained:

- Replace coolant circulation engine coolant temperature (ECT) thermal switch -

F51- or after-run coolant thermal switch -F95- with engine coolant temperature
(ECT) sensor -G2-.