Cooling system components Стр.
1 из 24
Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->
19 - 1
Cooling system components
Warning!
Hot steam may escape when opening expansion tank.
Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover sealing
cap with a rag and open carefully.
Note:
The cooling system is under pressure when engine
is warm. If necessary reduce pressure before repair.
Secure all hose connections using hose clamps
appropriate for the model type.
Hose clamp pliers V.A.G 1921 or Spring Type Clip
Pliers VAS 5024A are recommended for installing
spring clamps.
Replace gaskets and O-rings.
The arrows which are marked on coolant lines and
hoses must face 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, draining and refilling 19-1, Coolant, draining
and refilling
Coolant pump, removing and installing 19-1, Coolant
pump, 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
Cooling system components Стр. 2 из 24
system, checking for leaks
Cooling system components (on engine), assembly
overview
Mounting bolt
Mounting bolt
Coolant pipe
Connection hose
O-ring
Replace
Connection
10 Nm
Retaining clip
Cooling system components Стр. 3 из 24
O-ring
Replace
Engine Coolant Temperature
(ECT) Sensor G62
Connection hose
Connecting piece
Connection hose
Connection hose
Connection hose
Coolant pipe
5 Nm
Connection hose
Coolant pipe
5 Nm
Coolant distribution housing
With thermostat
Starts to open 87 C
15 Nm
Coolant pump
Removing and installing
19-1, Coolant pump,
removing and installing
15 Nm
Coolant Pump V50 , assembly overview
Cooling system components Стр. 4 из 24
3 Nm
Coolant pipe
Spring clip
Coolant line
To turbocharger
Coolant hose
Bracket
Coolant hose
Toward radiator inlet
Coolant Pump V50
Functioning can be checked
Cooling system components Стр. 5 из 24
via output Diagnostic Test
Mode (DTM) Vehicle
Diagnosis, Testing and
Information System VAS
5051
5 Nm
5 Nm
Cooling system components (on body), assembly
overview
Radiator
Removing and installing
19-1, Radiator, removing
and installing
After replacing, completely
replace coolant
Cooling system components Стр. 6 из 24
O-ring
Replace if damaged
Upper coolant hose
To connection sleeve at
cylinder head
Cap
Check using cooling system
tester V.A.G 1274 and
adapter V.A.G 1274/9
Pressure release valve must
open at a pressure of 1.4 to
1.6 bar.
Connector
5 Nm
Expansion tank
Perform leak test of cooling
system cooling system tester
V.A.G 1274 and adapter
V.A.G 1274/8
Lower coolant hose
To connection for coolant
regulator
5 Nm
5 Nm
Coolant Fan 2 V177
Removing and installing
19-1, Coolant Fan V7 and
Coolant Fan 2 V177 ,
removing and installing
Coolant Fan V7
Removing and installing
19-1, Coolant Fan V7 and
Cooling system components Стр. 7 из 24
Coolant Fan 2 V177 ,
removing and installing
With Coolant Fan Control
(FC) Control Module J293
Connector
Intake air elbow
Coolant hoses, connection diagram
Expansion tank
With sealing cap
Pressure relief valve in cap,
checking Item - 4 -
Turbocharger
Cooling system components Стр. 8 из 24
Removing and installing
21-1, Turbocharger,
removing and installing
Cylinder head/Cylinder block
After replacing, replace
coolant
Coolant connection
Heater core of heater
After replacing, replace
coolant
Bypass thermostat
Starts to open 80 C
Transmission oil cooler
Only with automatic
transmission
Engine oil cooler
Intake manifold
Removing and installing
24-1, Intake manifold,
removing and installing
Radiator
Removing and installing
19-1, Radiator, removing
and installing
After replacing, replace
coolant
Coolant Pump V50
Functioning can be checked
via output Diagnostic Test
Mode (DTM) Vehicle
Diagnosis, Testing and
Information System VAS
Cooling system components Стр. 9 из 24
5051
Coolant distribution housing
With thermostat
Coolant, draining and refilling
Special tools, testers and auxiliary items
required
Adapter V.A.G 1274/8
Drip tray V.A.G 1306
Spring type clip pliers VAS 5024A
Cooling system components Стр. 10 из 24
Cooling system filler unit VAS
6096
Refractometer T10007
Drain coolant 19-1, Drain coolant .
Fill with coolant 19-1, Fill with coolant
Drain coolant
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 sealing
cap with a rag and open carefully.
- Open cap of coolant expansion tank.
- Remove noise insulation
Repair Manual, Body Exterior, Repair Group 50, Front
body; noise insulation
- Disengage quick acting coupling - arrow - and
Cooling system components Стр. 11 из 24
disconnect coolant hose from cooler.
Fill with coolant
Note:
Only coolant additive G 12 plus (according to TL VW
774 F) must be used. Characteristic: purple coloring
G 12 plus (according to TL VW 774 F) may be mixed
with previous coolant additive G 12!
"G 12" 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 these reasons, the cooling system
must be filled with radiator freeze and corrosion
protection fluid all year round.
Especially in countries with tropical climates or when
vehicle is driven under heavy load, the coolant
improves the engine reliability by its increased
boiling point.
Freeze protection must be guaranteed to approx. -25
C (approx. -35 C in countries with an arctic
climate).
The coolant concentration must not be reduced by
adding water, even during the warmer season. The
coolant additive portion must be at least 40%.
If for climatic reasons 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 and cooling effectiveness
will be reduced.
If the radiator, heater core, cylinder head or cylinder
head gasket is replaced, completely replace the
engine coolant.
Recommended mixture ratios:
Frost protection Anti-freeze G 12 1) Water 1)
to amount
Cooling system components Стр. 12 из 24
-25 C 40% 3.2 l 4.8 l
-35 C 50% 4.0 l 4.0 l
1) Thequantity of coolant can vary depending upon vehicle
options.
- Install insulation pan
Repair Manual, Body Exterior, Repair Group 50, Front
body, noise insulation
Using cooling system filler unit VAS 6096 :
- Screw adapter V.A.G 1274/8 on to expansion tank.
- Fill coolant circuit using cooling system filling unit VAS
6096 Operating instructions for cooling system filler unit
VAS 6096 .
Without cooling system filler unit VAS 6096 :
- Slowly fill coolant up to top marking of hatched area on
expansion tank.
- Close expansion tank.
- Start engine and maintain an engine speed of about 2000
RPM for approx. 3 minutes.
- Let engine run until fan starts up.
Warning!
Hot steam may escape when opening expansion tank.
Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover sealing
cap with a rag and open carefully.
- Check coolant level and top off if necessary. With engine
Cooling system components Стр. 13 из 24
at operating temperature, coolant level must be at top
marking, with engine cold, it must be in center of hatched
area.
Coolant pump, removing and installing
Special tools, testers and auxiliary items required
Drip tray V.A.G 1306
Spring type clip pliers VAS 5024A
Coolant pump, removing 19-1, Coolant pump, removing
Coolant pump, installing 19-1, Coolant pump, installing
Coolant pump, removing
Warning!
Hot steam may escape when opening expansion tank.
Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover sealing
cap with a rag and open carefully.
- Drain engine coolant 19-1, Drain coolant .
Cooling system components Стр. 14 из 24
- Remove toothed belt 15-1, Toothed belt, removing and
installing .
- Remove mounting bolts - 1 - for coolant pump and
remove coolant pump - 2 - .
- Remove O-ring - 3 - .
Coolant pump, installing
Installation is in reverse order of removal, note the
following:
- Replace O-ring.
- Clean or smooth sealing surface for O-ring.
- Coat new O-ring - 3 - with coolant.
- Insert coolant pump - 2 - .
Installation position: Sealing plug in housing points
downward.
- Tighten bolts - 1 - of coolant pump.
- Install toothed belt 15-1, Toothed belt, removing and
installing .
Cooling system components Стр. 15 из 24
- Fill with coolant 19-1, Fill with coolant .
Tightening torques:
Component Nm
Coolant pump to cylinder block 15
Center toothed belt guard to cylinder block 10 1)
1) Insert with locking fluid
Coolant lines, removing and installing
Special tools, testers and auxiliary items required
Spring type clip pliers VAS 5024A
Removing
- Remove engine cover 24-1, Air filter/engine cover,
removing and disassembling .
- Remove pipe - A - and hose - B - - arrows - .
Cooling system components Стр. 16 из 24
- Loosen bolts - arrows - and remove charge air pipe with
hose downward.
- Drain engine coolant 19-1, Drain coolant .
- Disconnect electrical harness connectors - arrows - .
- Disconnect coolant hoses from coolant pipes - arrows -
.
Cooling system components Стр. 17 из 24
- Disconnect hose - A - and remove bolt - B - . Remove
front coolant pipe.
- Disengage connector - A - from bracket, disconnect
hose - B - and remove bolts - C - . Remove rear coolant
pipe.
Installing
Installation is performed in reverse order of removal.
Coolant distribution housing with thermostat, removing
and installing
Removing
- Remove generator
Repair Manual, Electrical Equipment, Repair Group 27,
Generator
- Disconnect coolant lines 19-1, Coolant lines, removing
and installing .
Cooling system components Стр. 18 из 24
- Disconnect coolant hose - 2 - from coolant transfer case.
To do so, pull out retaining clip - 1 - .
- Remove bolts - arrows - and remove coolant distribution
housing with thermostat from engine.
Installing
- Clean sealing surface for O-ring.
- Replace O-ring and coat it with coolant.
- Place coolant distribution housing on engine block and
tighten bolts uniformly to 15 Nm.
- Installation is in reverse order of removal.
Coolant Fan V7 and Coolant Fan 2 V177 , removing and
installing
Coolant fan, removing
- Remove engine cover.
Cooling system components Стр. 19 из 24
- Remove upper mounting bolts of air intake elbow -
arrows - .
- Remove noise insulation
Repair Manual, Body Exterior, Repair Group 50, Front
body; noise insulation
- Disconnect harness connector - 1 - and remove lower
mounting bolts of intake air elbow - arrows - .
- Remove intake air elbow downward.
Cooling system components Стр. 20 из 24
- Disconnect electrical harness connector - 1 - and lay
cable free.
- Remove nuts - arrows - and remove fans.
Fan, installing
Installation is in reverse of removal, note the following:
Tightening torques:
Component Nm
Coolant fan to intake air elbow 10
Intake air elbow to radiator 5
Radiator, removing and installing
Special tools, testers and auxiliary items
required
Refractometer T10007
Cooling system components Стр. 21 из 24
Drip tray V.A.G 1306
Spring Type Clip Pliers VAS
5024A
Cooling system filler unit VAS
6096
Adapter V.A.G 1274/8
Radiator, removing
- Drain engine coolant 19-1, Coolant, draining and
refilling .
- Disconnect charge air hoses - arrows - .
- Bring lock carrier into service position
Repair Manual, Body Exterior, Repair Group 50, Body
front, lock carrier service position.
- Disconnect coolant hoses from cooler.
- Remove intake air elbow with coolant fans 19-1,
Coolant Fan V7 and Coolant Fan 2 V177 , removing and
installing .
Note:
Do not bend or stretch lines or hoses as condenser
and/or refrigerant lines/hoses may be damaged.
Cooling system components Стр. 22 из 24
- Remove bolts - arrows - from radiator.
- Remove radiator downward.
Radiator, installing
Installation is in reverse order of removal, note the
following:
- When installing a new radiator, old coolant must not be
reused.
- Fill with coolant 19-1, Fill with coolant .
Tightening torques:
Component Nm
Radiator mounting to lock carrier 5
Condenser to radiator 5
Intake air elbow to radiator 5
Cooling system, checking for leaks
Cooling system components Стр. 23 из 24
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
Pressure relief valve in cap, checking 19-1, Checking
pressure relief valve in sealing cap
Engine at operating temperature.
Test sequence:
Warning!
Cooling system components Стр. 24 из 24
Hot steam may escape when opening expansion tank.
Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover sealing
cap with a rag and open 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
- Position cooling system tester V.A.G 1274 with adapter
V.A.G 1274/9 on cap.
- Pump using hand pump.
Pressure release valve must open at a positive
pressure of 1.4 to 1.6 bar.
Volkswagen Technical Site: [Link] [Link] [Link]
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