2.0L - Cooling System - Engine Code(s): Bpy: Maintenance Volkswagen Eos I

DRAINING AND FILLING

Special tools and workshop equipment required

1. Refractometer T10007
2. Drip Tray V.A.G 1306
3. Spring Type Clip Pliers VAS 5024 A
4. Cooling System Charge Unit VAS 6096
5. Adapter V.A.G 1274/8

Draining

Note. Drained coolant must be stored in a clean container for disposal or reuse. Follow disposal regulations.

Open the cap for the coolant expansion tank cap.

Remove the noise insulation. Refer to Description and Operation .

Disengage the quick acting coupling -arrow- and disconnect the coolant hose from the radiator.

Scheme 1

Also remove the hose -arrow- at the oil cooler.

Scheme 2

Filling

Note. On vehicles from Model Year (MY) 2008, only coolant additive G 12 plus-plus conforming to TL VW 774 G may be used. On vehicles through MY 2007, coolant additive G 12 plus conforming to TL VW 774 F and G 12 plus-plus conforming to TL VW 774 G may be used. G 12 plus-plus may be mixed with the previous coolant additive G 12 plus. Both are colored purple. Coolant additives marked with "Conforms to TL VW 774 G" or "Conforms to TL VW 774 F" prevent freezing and corrosion damage and scaling and they increase the boiling point. The cooling system must be filled with coolant additive year-round. 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 down to approximately -25°C (-13°F) (in arctic climatic countries down to approximately -35°C (-31°F). 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%. If for climatic reasons a greater frost protection is required, the amount of coolant additive of can be increased, but only up to 60% (frost protection to about -40°C (-40°F)), as otherwise frost protection is reduced again and cooling effectiveness is also reduced. The refractometer T10007 is recommended for determining freeze protection density. If the radiator, heater core, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.

Recommended Mixture Ratios

Reconnect the hose and connector coupling

Install the noise insulation. Refer to Description and Operation .

Filling with the Cooling System Charge Unit VAS 6096

Install the adapter V.A.G 1274/8 onto the expansion tank.

Fill the coolant circuit using the cooling system charge unit VAS 6096. Refer to the operating instructions for the cooling system charge unit VAS 6096.

Filling without the Cooling System Charge Unit VAS 6096

Slowly fill the coolant up to the top mark of the hatched area on the expansion tank.

Scheme 3

Install the expansion tank cap.

Start the engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.

Allow the engine to run until the coolant fan -V7- starts running.

Check the coolant level and fill if necessary. With the engine at operating temperature, the coolant level must be at the top mark, with the engine cold, it must be in the center of the hatched area.

Scheme 4

1. Expansion Tank With the sealing cap. Pressure relief valve in cap, checking. Refer to «PRESSURE RELIEF VALVE IN CAP, CHECKING»(ref-475529-S36728853242012052300000) .
2. Turbocharger Removing and installing, refer to «TURBOCHARGER»(ref-475534-S40636796932012052300000) .
3. Cylinder Head/Cylinder Block Replace coolant after replacing.
4. Coolant Connection
5. Heater Core Replace coolant after replacing.
6. Bypass Thermostat Only with a automatic transmission. Checking, refer to «BYPASS THERMOSTAT OVERVIEW»(ref-475529-S23691330612012052300000) .
7. Transmission Oil Cooler Only with a automatic transmission.
8. Engine Oil Cooler
9. Intake Manifold Removing and installing, refer to emoving and installing «INTAKE MANIFOLD»(ref-475526-S38480181432012052300000) .
10. Radiator Removing and installing, refer to one of the following: GTI and Eos, refer to «RADIATOR»(ref-475529-S26147476472012052300000) . Replace the coolant after replacing.
11. Coolant Recirculation Pump -V50- The direction of coolant flow in the after-run operation is opposite the illustrated direction of flow. The functions can be checked with output Diagnostic Test Mode (DTM). Refer to the vehicle diagnosis, testing and information system VAS 5051.
12. Coolant Thermostat Housing With the coolant thermostat. Coolant thermostat, checking. Refer to "Function and Component Selection" in the vehicle diagnosis, testing and information system VAS 5051.

Scheme 5

1. Cap Pressure relief valve in cap, checking. Refer to «PRESSURE RELIEF VALVE IN CAP, CHECKING»(ref-475529-S36728853242012052300000) .
2. Connector
3. Stud Bolt 5 Nm
4. Expansion Tank Cooling system, checking for leaks. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-475529-S37727060092012052300000) .
5. Sealing Strip Only on the Passat.
6. O-ring Replace if damaged.
7. Lower Coolant Hose To the coolant thermostat housing.
8. Nut 5 Nm
9. Bolt 5 Nm
10. Coolant Fan 2 -V177- Removing and installing, refer to «COOLANT FAN AND COOLANT FAN 2»(ref-475529-S39781014832012052300000) .
11. Coolant Fan -V7- Removing and installing, refer to «COOLANT FAN AND COOLANT FAN 2»(ref-475529-S39781014832012052300000) . With the coolant fan control module.
12. Connector
13. Fan Shroud
14. Radiator Removing and installing, refer to «RADIATOR»(ref-475529-S26147476472012052300000) . After replacing, replace the entire amount of coolant.
15. Upper Coolant Hose To the connecting piece on the cylinder head.

Scheme 6

1. Bolt 40 Nm
2. Bolt 30 Nm
3. Coolant Pipe
4. Connecting Hose
5. O-ring Replace
6. Connecting Piece
7. Bolt 10 Nm
8. Retaining Clip
9. O-ring Always replace
10. Engine Coolant Temperature Sensor -G62
11. Connecting Hose
12. Connecting Piece
13. Connecting Hose
14. Connecting Hose
15. Connecting Hose
16. Coolant Pipe
17. Bolt 5 Nm
18. Connecting Hose
19. Coolant Pipe
20. Bolt 5 Nm
21. Coolant Thermostat Housing With the coolant thermostat. Coolant thermostat, checking. Refer to "Function and Component Selection" in the vehicle diagnosis, testing and information system VAS 505. Opening begins at 87°C (188.6°F).
22. Bolt 15 Nm
23. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(ref-475529-S02780795972012052300000) .
24. Bolt 15 Nm

Scheme 7

1. Nut 3 Nm
2. Coolant Pipe
3. Spring-Type Clip
4. Coolant Line To the turbocharger.
5. Spring-Type Clip
6. Coolant Hose With the bypass thermostat. Bypass thermostat, checking. Refer to «BYPASS THERMOSTAT OVERVIEW»(ref-475529-S23691330612012052300000) .
7. Nut 5 Nm
8. Engine Coolant Temperature Sensor on Radiator -G83
9. Retaining Clip
10. O-ring Always replace
11. Lower Coolant Hose
12. T Connection
13. Coolant Hose
14. Bracket
15. Coolant Recirculation Pump The functions can be checked with output Diagnostic Test Mode (DTM). Refer to the vehicle diagnosis, testing and information system VAS 5051.
16. Coolant Hose
17. Bolt 8 Nm

Scheme 8

1. Nut 3 Nm
2. Coolant Line
3. Spring-Type Clip
4. Coolant Line To the turbocharger.
5. Coolant Hose
6. Bracket
7. Coolant Hose To the radiator inlet.
8. Coolant Recirculation Pump The functions can be checked with output Diagnostic Test Mode (DTM). Refer to the vehicle diagnosis, testing and information system VAS 5051.
9. Bolt 8 Nm
10. Nut 5 Nm

Scheme 9

1. Retaining Clip
2. Lower Part of Housing
3. Operating Element
4. Spring
5. O-ring
6. Upper Part of Housing

Checking the Bypass Thermostat

Remove the operating element.

Warm the operating element in a coolant bath.

Starts to open: approximately 75°C (167°F).

Opening end: approximately 85°C (185°F).

Opens: approximately 5 mm

Bypass Thermostat Location

The bypass thermostat for the transmission fluid cooler circuit

Arrow on the bottom part of the thermostat points to the heater core.

The bypass thermostat for the turbocharger coolant circuit

Arrow on the bottom part of the housing points to the coolant recirculation pump.