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

COOLING SYSTEM, CHECKING FOR LEAKS

Special tools and workshop equipment required

1. Cooling System Tester V.A.G 1274
2. Adapter V.A.G 1274/8
3. Adapter V.A.G 1274/9

Pressure relief valve in cap, checking. Refer to PRESSURE RELIEF VALVE IN CAP, CHECKING .

1. Engine is at operating temperature.

Test Sequence

Open the cap on the coolant expansion tank.

Install the cooling system tester V.A.G 1274 with the adapter V.A.G 1274/8 onto the expansion tank.

Scheme 10

Generate a positive pressure of approximately 1.0 bar using the hand pump on the tester.

If the pressure drops

Search for leaking areas and repair the malfunction.

Scheme 11

Install the cap to the adapter V.A.G 1274/9 and the cooling system tester V.A.G 1274.

Operate the hand pump.

1. The relief valve must open at 1.4 to 1.6 bar.

COOLANT PUMP

Special tools and workshop equipment required

1. Drip Tray V.A.G 1306
2. Spring Type Clip Pliers VAS 5024 A

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the toothed belt, refer to one of the following

1. With a divided toothed belt guard, refer to «TOOTHED BELT, WITH A DIVIDED TOOTHED BELT GUARD»(ref-475573-S37549153822012052300000) .
2. Without a divided toothed belt guard, refer to «TOOTHED BELT, WITHOUT A DIVIDED TOOTHED BELT GUARD»(ref-475573-S38716620892012052300000) .

Remove the coolant pump bolts -1- and remove the coolant pump -2-.

Scheme 12

Remove the O-ring -3-.

Installing

Install in the reverse order of removal. Note the following

Replace the O-ring.

Clean the smooth sealing surface for the O-ring.

Lubricate the new O-ring -3- with coolant.

Insert the coolant pump -2-.

1. Installed position: the Sealing plug in the housing points downward.

Tighten the coolant pump bolts -1 -.

Install the toothed belt, refer to one of the following

1. With a divided toothed belt guard, refer to «TOOTHED BELT, WITH A DIVIDED TOOTHED BELT GUARD»(ref-475573-S37549153822012052300000) .
2. Without a divided toothed belt guard, refer to «TOOTHED BELT, WITHOUT A DIVIDED TOOTHED BELT GUARD»(ref-475573-S38716620892012052300000) .

Fill the coolant. Refer to DRAINING AND FILLING .

Tightening Specifications

COOLANT PIPES

Special tools and workshop equipment required

1. Spring Type Clip Pliers VAS 5024 A

Removing

Remove the engine cover/upper air filter housing. Refer to ENGINE COVER/UPPER AIR FILTER HOUSING .

GTI

Remove the pipe -A- and hose -B- bolts -arrows-.

Scheme 13

Continuation for all Vehicles

Remove the noise insulation. Refer to Description and Operation .

Disconnect the connector -3- from the charge air pressure sensor -G31-.

Scheme 14

Remove the bolts -2 and 4-.

Loosen the clamp -1-, disconnect the quick-release coupling on the charge air cooler and remove the charge air pipe with the hose downward.

Drain the coolant. Refer to DRAINING AND FILLING .

Disconnect the electrical connectors -arrow-.

Scheme 15

Disconnect the coolant hoses from the coolant pipes -arrows-.

Scheme 16

Disconnect the hose -A- and remove the bolt -B-. Remove the front coolant pipe.

Scheme 17

Disengage the connector -A- from the bracket, disconnect the hose -B- and remove the bolts -C-. Remove the rear coolant pipe.

Scheme 18

Installing

Installation is performed in reverse order.

COOLANT THERMOSTAT HOUSING WITH THERMOSTAT

Note. Check the coolant thermostat. Refer to "Function and component selection" in the vehicle diagnosis, testing and information system VAS 5051.

Removing

Remove the generator. Refer to Removal and Installation .

Remove the coolant pipes. Refer to COOLANT PIPES .

Remove the clamp -1- and then remove the coolant hose -2- from the coolant thermostat housing.

Scheme 19

Remove the bolts -arrows- and remove the coolant thermostat housing with the thermostat from the engine.

Scheme 20

Installing

Clean the sealing surface for the O-ring.

Replace the O-ring and lubricate it with coolant.

Install the coolant thermostat housing to the cylinder block and tighten the bolts evenly to 15 Nm.

Further installation is in the reverse order of removal.

COOLANT FAN AND COOLANT FAN 2

Removing

Remove the upper fan shroud bolts -upper arrows-. Loosen the refrigerant pipes and move them to the side if necessary.

Scheme 21

Remove the noise insulation. Refer to Description and Operation .

Disconnect the harness connector -1- and remove the lower fan shroud bolts -lower arrows-.

Remove the fan shroud downward.

Disconnect the electrical harness connector -1- and lay the wire to the side.

Scheme 22

Remove the nuts -arrows- and remove the coolant fans.

Installing

Install in reverse the order of removal. Note the following

RADIATOR

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

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Disconnect the charge air hose -arrows-.

Scheme 23

Move the lock carrier into the service position. Refer to Description and Operation .

Remove the coolant hoses from the radiator.

Remove the fan shroud and fans. Refer to COOLANT FAN AND COOLANT FAN 2 .

Note. To prevent damage to the condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

Remove the bolts -arrows- from the radiator.

Scheme 24

Remove the radiator downward.

Installing

Install in reverse order of removal. Note the following

Do not use the old coolant if a new radiator is being installed.

Fill the coolant. Refer to DRAINING AND FILLING .

Scheme 25

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

Scheme 26

Special tools and workshop equipment required

1. Cooling System Tester V.A.G 1274
2. Adapter V.A.G 1274/8
3. Adapter V.A.G 1274/9