3.2L - Cooling System - Engine Code(s): Bub & Cbra: Other Volkswagen Eos I

COOLING SYSTEM COMPONENTS

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before beginning any repair work. Hoses are secured with spring type clips. In cases of repair, only use spring type clips. Hose clip pliers -VAS 6340- or spring type clip pliers -VAS 5024 A- are recommended for installing the spring type clips. While installing, route the coolant hoses free of tension and without them coming into contact with other components. The arrows on the coolant pipes and coolant hoses must line up across from each other. Always replace gaskets and seals.

Perform a leakage test on the cooling system using the cooling system tester -V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G 1274/9-.

COOLING SYSTEM, CHECKING FOR LEAKS

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

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

Test Conditions

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 40

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

If the pressure drops

Search for leaking areas and repair the malfunction.

PRESSURE RELIEF VALVE IN CAP, CHECKING

Install the cooling system tester -V.A.G 1274- with the adapter -V.A.G 1274/9- onto the cap.

Scheme 41

Operate the hand pump.

1. The pressure release valve must open at 1.4 to 1.6 bar.

AFTER-RUN COOLANT PUMP, CHECKING

Special tools and workshop equipment required

1. Voltage Tester -V.A.G 1527 B
2. Connector Test Set -V.A.G 1594 C
3. Wiring Diagram

Test Conditions

1. The fuses must be OK.

Test Sequence

Remove the noise insulation. Refer to Removal and Installation .

Disconnect the 2 pin connector from the after-run coolant pump -V51-.

Connect the contacts of the after-run coolant pump to the battery, using adapter cables from the connector test set -V.A.G 1594 C-.

Scheme 42

1. The after-run coolant pump must run.

If the after-run coolant pump does not start running

Replace the after-run coolant pump.

If the after-run coolant pump does starts running

Turn the ignition off and then on again.

Connect the voltage tester -V.A.G 1527 B- and the adapter cables from the connector test kit -V.A.G 1594 C- to the connector, which was disconnected from the after-run coolant pump.

Scheme 43

1. The Light Emitting Diode (LED) must light up.

Note. This test must be performed inside of 10 min. after the ignition has been turned off.

If the LED does not light up

Locate and repair the open circuit in the wiring using the wiring diagram.

COOLANT THERMOSTAT HOUSING

Special tools and workshop equipment required

1. Hose Clip Pliers -V.A.G 1921
2. Drip Tray for -VAS 6100- -VAS 6208

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Disconnect the battery ground (-) cable with the ignition turned off. Refer to Removal and Installation .

Remove the air guide cover -1-, disengage the clips to do so.

Scheme 44

Remove the intake air duct -2-.

Remove the air filter housing and connecting pipe, while doing this remove the bolt -A-, disconnect the connector -B- and remove the spring clip -C-. When reinstalling, observe the mark -D-.

Scheme 45

Pull the air filter housing upward.

Disconnect the vacuum line -arrow- at the variable intake manifold actuator.

Scheme 46

Remove the bolts -1 and 2- and remove the vacuum actuator from the intake manifold.

Disconnect the electrical connector -arrow- from the engine coolant temperature sensor -G62-.

Scheme 47

Disconnect the secondary air injection hose at the position indicated by the -arrow-.

Scheme 48

Free up air the hose from the bracket.

Disconnect the coolant hoses at the positions indicated by the -arrows-.

Scheme 49

Remove the bolts -arrows-.

Scheme 50

Pull the transmission oil cooler coolant pipe bracket toward the left.

Swing the secondary air injection system hose bracket forward.

Remove the bolt -arrow- from the wiring harness bracket.

Scheme 51

Remove the coolant thermostat housing -2- while pressing the coolant pipe -1- toward the coolant pump with a pry bar.

Scheme 52

Installing

Installation is carried out in the reverse order while noting the following

Note. Replace the seals.

Fill the coolant. Refer to DRAINING AND FILLING .

Connect the battery. Refer to Removal and Installation .

Tightening Specifications

COOLANT THERMOSTAT

Removing

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

Remove the thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Remove the bolts -arrows- and remove the adapter -1-.

Scheme 53

Remove the O-ring -3- together with the coolant thermostat -2- from the coolant thermostat housing -1-.

Scheme 54

Installing

Installation is carried out in the reverse order while noting the following

Note. Always replace gaskets and seals.

Clean the O-ring sealing surfaces.

Insert the thermostat.

1. Installed position: Align the breather valve -arrow- as shown in the illustration.

Coat the new O-ring -1- with coolant.

Install the adapter to the coolant thermostat housing.

Install the thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Tightening Specifications

COOLANT PIPE

Removing

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

Remove the thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Remove the secondary air injection pump motor -V101-. Refer to Secondary Air Injection Pump Motor -V101 .

Remove the ribbed belt. Refer to RIBBED BELT .

Disconnect the electrical connector -1- for the Air Conditioning (A/C) clutch on the A/C compressor and free up the electrical wire.

Scheme 55

Remove the compressor bolts -arrow-.

Secure the A/C compressor to the front of the longitudinal member with the refrigerant lines connected.

Disconnect for engine speed sensor -G28- connector -arrow- from bracket on the oil dipstick guide tube.

Scheme 56

Remove the bolt -3- and remove the oil dipstick guide tube -2-.

Scheme 57

Remove the bolt -4- and remove the vacuum reservoir -1- from the intake manifold.

Move the vacuum reservoir with the lines still connected to the side.

Disconnect the electrical connector -3- from the after-run coolant pump -V51- -2-.

Scheme 58

Remove the pump downward from the rubber bracket loops. Spray the rubber loops with silicone-free lubricant if necessary.

Remove the after-run coolant pump bracket.

Unclip the wire harness retainer on the right from the coolant pipe.

Remove the wire harness on the left from the retainer on the coolant pipe.

Remove the coolant hose to the oil cooler at the coolant pipe.

Remove the coolant pipe from the cylinder block.

Installing

Installation is carried out in the reverse order while noting the following

Note. Replace the O-rings.

Clean and/or smooth the O-ring sealing surface in the cylinder block before installing.

Coat the new O-ring -1- with coolant and slide it onto the coolant pipe -2-.

Scheme 59

Slide the coolant pipe into the hole in the cylinder block.

Install the thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Install the A/C compressor. Refer to Removal and Installation .

Install the ribbed belt. Refer to RIBBED BELT .

Fill the coolant. Refer to DRAINING AND FILLING .

Tightening Specifications

COOLANT PUMP

Special tools and workshop equipment required

1. Engine Support Bridge -10-222 A
2. Adapter -10-222 A/18
3. Shackle -10-222 A/12
4. Bracket with Spindle and Hook -10- 222 A/10
5. Adapter -10-222 A/13
6. Refractometer -T10007
7. Drip Tray for -VAS 6100- -VAS 6208
8. Torque Wrench (5-50 Nm) -V.A.G 1331
9. Torque Wrench (40-200 Nm) -V.A.G 1332
10. Spring Type Clip Pliers -VAS 5024 A

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the right front sections of the wheel housing liners. Refer to Removal and Installation .

Scheme 60

Remove the ribbed belt. Refer to RIBBED BELT .

Install the engine support bridge -10-222 A- with the bracket with spindle and hook -10-222 A/10-, the shackle -10-222 A/12-, adapter -10-222 A/13- and the adapter -10-222 A/18- as shown and support the engine in its installed position using the right lifting eye.

Scheme 61

Remove the engine mount to engine mount bracket bolts -arrows-.

Scheme 62

Lower the engine 40 mm using the engine support bridge -10-222 A-.

Remove the coolant pump pulley. To do so, counter hold the pulley using a drift (standard).

Remove the coolant pump bolts -1-.

Scheme 63

Remove the coolant pump -A- as shown.

Scheme 64

Installing

Installation is carried out in the reverse order while noting the following

Lubricate the new O-ring with coolant.

Install the coolant pump.

Tighten the coolant pump bolts. Tightening specification: 8 Nm

Install the coolant pump pulley. Tightening specification: 20 Nm

Raise the engine using the engine support bridge -10-222 A- and position it with new bolts.

Align the engine mount as follows

Scheme 65

1. There must be a distance of at least 10 mm -a- present between the engine mount bracket and right longitudinal member.
2. The casting edge on the engine mount bracket -2- must be parallel to the engine mount support arm -1-.

Note. For the engine mount tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS .

Install the ribbed belt. Refer to RIBBED BELT .

Fill the coolant. Refer to DRAINING AND FILLING .

FAN SHROUD AND FANS

Special tools and workshop equipment required

1. Torque Wrench (5-50 Nm) -V.A.G 1331

Removing

Remove the noise insulation. Refer to Removal and Installation .

Unclip the coolant hose from the fan shroud.

Remove the air guide from the air filter housing. Refer to AIR FILTER HOUSING OVERVIEW .

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

Scheme 66

Remove the fan shroud with fans.

Disconnect the harness connector -1- and lay the wires free.

Scheme 67

Remove the nuts -arrows- and remove fans, if required.

Installing

Installation is carried out in the reverse order while noting the following

Tightening Specifications

RADIATOR

Special tools and workshop equipment required

1. Refractometer -T10007
2. Adapter -V.A.G 1274/8
3. Drip Tray -V.A.G 1306
4. Torque Wrench (5-50 Nm) -V.A.G 1331
5. Spring Type Clip Pliers -VAS 5024 A
6. Cooling System Charge Unit -VAS 6096

Removing

Remove the noise insulation. Refer to Removal and Installation .

Remove the front bumper. Refer to Removal and Installation .

Bring the lock carrier into the service position. Refer to "Lock Carrier" in Description and Operation .

Drain the coolant. Refer to DRAINING AND FILLING .

Disconnect all coolant hoses from the radiator.

Remove the coolant fan shroud and fans. Refer to FAN SHROUD AND FANS .

Remove the bolts -1- from the brackets.

Scheme 68

Swing the radiator slightly toward the rear.

Remove the Air Conditioning (A/C) condenser bolts -2-.

Remove the side bolt -arrow- from the A/C condenser to the radiator.

Scheme 69

Take the radiator up and out.

Installing

Installation is carried out in the reverse order while noting the following

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

Fill with coolant. Refer to DRAINING AND FILLING .