2.0L - Cooling System - Engine Code(s): Cjaa: Other Volkswagen Golf Mk7

COOLING SYSTEM, CHECKING FOR LEAKS

Special tools and workshop equipment required

1. Cooling System Tester V.A.G 1274 B
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 adapter V.A.G 1274/8 on the coolant expansion tank.

Clamp the connecting piece V.A.G 1274 B/1 on the adapter V.A.G 1274/8.

Connect the connector piece V.A.G 1274 B/1 to the cooling system tester V.A.G 1274 B using the connecting hose.

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

If the pressure drops

Check for leaks inside the engine compartment and under the vehicle. Remove the noise insulation if necessary.

Pressure Relief Valve in Cap, Checking

Install the cap to the adapter V.A.G 1274/9.

Clamp the connecting piece V.A.G 1274 B/1 to the adapter V.A.G 1274/9.

Connect the connector piece V.A.G 1274 B/1 to the cooling system tester V.A.G 1274 B using the connecting hose.

Using the hand pump from the cooling system cooling system tester, build the maximum pressure according to the vehicle/engine combinations listed in the following table

The pressure relief valve must not open yet.

If the pressure relief valve opens prematurely

Replace the cap.

Build the pressure according to the vehicle/engine combination listed in the table.

The pressure relief valve must open when the specified pressure is exceeded.

If the pressure relief valve does not open

Replace the cap.

OIL COOLER, CHECKING FOR LEAKS

Special tools and workshop equipment required

1. Refractometer T10007
2. Hose Clamps up to 25 mm Dia. 3094
3. Cooling System Tester V.A.G 1274
4. Adapter V.A.G 1274/8
5. Hose Clip Pliers VAS 6340
6. Drip Tray for VAS 6100 VAS 6208
7. Torque Wrench (5-50 Nm) V.A.G 1331

Conditions

1. Cold engine

Test Sequence

Remove the noise insulation.

Disconnect the supply and return line from the oil cooler using the hose clamps up to 25 mm dia. VAS 3094.

Scheme 14

Loosen the hose clips -arrows- using the hose clip pliers VAS 6340.

Note. Catch any coolant running out with the drip tray V.A.G 1306 or drip tray for VAS 6100 VAS 6208.

Disconnect the coolant hoses from the oil cooler.

Install the cap -5- on the rear connection of the oil cooler -4-.

Scheme 15

Install the cap -2- on the expansion tank vent -1- connection.

Attach the coolant hose -3- to the oil cooler and to the expansion tank.

Fill the expansion tank up to the "MAX" mark.

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

Build a pressure of approximately 1.4 bar using the tester hand pump.

Watch the pressure decrease on the pressure gauge. The pressure must not fall within 10 minutes.

If the pressure drops

Replace the oil cooler. Refer to OIL FILTER BRACKET AND OIL COOLER OVERVIEW .

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

Check the coolant level; fill if necessary. Refer to DRAINING AND FILLING .

COOLANT PUMP

Special tools and workshop equipment required

1. Refractometer T10007
2. Hose Clip Pliers VAS 6340
3. Torque Wrench (5-50 Nm) V.A.G 1331

Removing

Note. Always replace gaskets and seals.

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the ribbed belt. Refer to one of the following

RIBBED BELT (WITH TENSIONER) .

RIBBED BELT (WITH TENSIONING ROLLER) .

Remove the toothed belt. Refer to TOOTHED BELT .

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

Scheme 16

Installing

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

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

Place the coolant pump -2- into the cylinder block and tighten the bolts -1- to 15 Nm.

Note. The sealing plug in the coolant pump faces downward.

Install the toothed belt. Refer to TOOTHED BELT .

Install the ribbed belt. Refer to one of the following

RIBBED BELT (WITH TENSIONER) .

RIBBED BELT (WITH TENSIONING ROLLER) .

Fill with coolant. Refer to DRAINING AND FILLING .

COOLANT THERMOSTAT

Special tools and workshop equipment required

1. T Bar and Socket 10 mm 3185
2. Refractometer T10007
3. Hex Ball Socket T10058
4. Torque Wrench (5-50 Nm) V.A.G 1331
5. Drip Tray for VAS 6100 VAS 6208
6. Hose Clip Pliers VAS 6340

Removing

Note. Always replace gaskets and seals.

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the throttle valve control module -J338-. Refer to INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW .

Remove the coolant hose from the connecting piece.

Loosen the connecting piece bolts -4- using the T bar and socket 10 mm 3185, remove using the hex ball socket T10058 and remove the connecting piece -3- with the coolant thermostat -1-.

Scheme 17

Turn the thermostat -1- 90° to the left and remove it from the connecting piece -3-.

Installing

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

Lubricate the new O-ring -2- with coolant.

Insert the thermostat -1- into the connecting piece -3- and turn it 90° to the right.

Note. The clip on the thermostat must be positioned at approximately a right angle.

Insert the connecting piece -3- with the coolant thermostat -1- in the cylinder block.

Tighten the bolts -4- using the T bar and socket 10 mm 3185. Tightening specification: 15 Nm

Fill the coolant. Refer to DRAINING AND FILLING .

4/2-WAY VALVE WITH THERMOSTAT

Removing

Special tools and workshop equipment required

1. Jointed Bit (XZN 8) T10445

Note. The thermostat is inside the 4/2-way valve and cannot be replaced separately.

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the generator. Refer to Removal and Installation .

Remove the throttle valve control module -J338-. Refer to INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW .

Remove the coolant hoses from the connections -A, B and D-.

Loosen the bolt on the coolant pipe behind the oil filter a few turns. Use the jointed socket (XZN 8) T10445.

Remove the coolant pipe from the connection -C-.

Scheme 18

Remove the bolts -3- for the 4/2-way valve -2-.

Pull the valve out of the cylinder block and then to the left in order to remove the connection -C- from the coolant pipe.

Installing

Note. Always replace gaskets and seals.

First, attach the 4/2-way valve and the connection -C- to the coolant pipe and then install them in the cylinder block.

Install the bolts -3- and tighten them to 15 Nm.

Connect the coolant hoses as follows

1. A- : Bypass line to the cylinder head
2. B- : Expansion tank
3. D- : Radiator return line

Tighten the bolt on the coolant pipe behind the oil filter. Use the jointed socket (XZN 8) T10445. Tightening specification: 10 Nm.

Fill the cooling system. Refer to DRAINING AND FILLING .

Install the throttle valve control module. Refer to INTAKE MANIFOLD AND ATTACHMENTS OVERVIEW .

Install the generator. Refer to Removal and Installation .

FAN SHROUD AND FANS

Removing

Remove the bolts -upper arrows- from the top of the fan shroud.

Scheme 19

Remove the noise insulation. Refer to Description and Operation .

Remove the hot side charge air hose from the charge air pipe. Loosen the hose clamp -2- and lift the circlip -1-.

Scheme 20

Disconnect the connector -1-.

Remove the bottom bolts -lower arrow-.

Remove the fan shroud and the fans.

Disconnect the connector -1- and (if equipped) -2- and free up the wires.

Scheme 21

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

Installing

Install in reverse order of removal.

RADIATOR

Special tools and workshop equipment required

1. Refractometer T10007
2. Hose Clip Pliers VAS 6340
3. Torque Wrench (5-50 Nm) V.A.G 1331/

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the coolant hoses from the radiator.

Disconnect the connector for the coolant fan.

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

Remove the radiator bolts and remove the radiator.

Installing

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

Fill the coolant. Refer to DRAINING AND FILLING .