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Home/Volkswagen/Jetta/Volkswagen Jetta IV (1998-2005)/Repair manual/1.8L - Engine Mechanical, Engine Code(s): Awd, Aww, Awp (A4 Platform)/Cooling system components
Contents Wiring diagrams Section: 1.8L - Engine Mechanical, Engine Code(s): Awd, Aww, Awp (A4 Platform) All sections

Cooling system components Volkswagen Jetta IV

1.8L - Engine Mechanical, Engine Code(s): Awd, Aww, Awp (A4 Platform) 2 illustrations ~733 words

Cooling system components

CAUTIONWhen doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. Ensure sufficient clearance to all moving or hot components.
CAUTIONHot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a rag and open very carefully.

Note. When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work. Hoses are secured with spring-type clips. In cases of repair only use spring-type clips. Hose clamp pliers V.A.G 1921 or pliers for spring clamps VAS 5024 A are recommended for installing spring clamps. When installing coolant hoses, make sure they are free of stress and do not come into contact with other components (observe markings on coolant connections and hoses).

Perform cooling system leakage test with Cooling System Tester V.A.G 1274 and Adapter V.A.G 1274/8 and Adapter V.A.G 1274/9.

Cooling system components, body side, refer to Cooling system components (on body), assembly overview

Cooling system components, engine side, refer to Cooling system components (on engine), assembly overview

Coolant hose connection diagram, refer to Coolant hose connection diagram

Coolant, draining and refilling, refer to Cooling system, draining and filling

Coolant mixture specifications, refer to Cooling system, draining and filling

Scheme 589

Scheme 589: Cooling system components (on body), assembly overview
Scheme 589: Cooling system components (on body), assembly overview

1 - Radiator

  1. Removing and installing, refer to «Radiator, removing and installing»(ref-255004-S39251418832007052300000)
  2. After replacing replace entire amount of coolant

2 - O-ring

  1. Replace if damaged

3 - Upper coolant hose

  1. Secured to radiator with a retaining clip
  2. Ensure seated tightly
  3. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

4 - Air shroud

5 - 10 Nm

6 - Auxiliary fan

  1. Only vehicles with optional equipment

7 - Fan ring

8 - Retaining clip

  1. Check for secure seat

9 - Connector

10 - Radiator fan

11 - Bracket

  1. For fan connector

12 - Lower coolant hose

  1. Secured to radiator with a retaining clip
  2. Ensure seated tightly
  3. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

13 - O-ring

  1. Replace

14 - Coolant fan control (FC) thermal switch F18 , 35 Nm

  1. For electric fan
  2. Switch temperatures
  3. 1st stage on: 92 to 97 ° C, off: 84 to 91 ° C
  4. 2nd stage on: 99 to 105, off: 91 to 98 ° C

15 - Bracket

  1. For radiator
  2. Note installation position

16 - 15 Nm

Scheme 590

Scheme 590: Cooling system components (on engine), assembly overview
Scheme 590: Cooling system components (on engine), assembly overview

1 - 15 Nm

2 - Toothed belt

  1. Mark direction of rotation before removing
  2. Check for wear
  3. Do not kink
  4. Removing and installing, tensioning, refer to «Toothed belt, removing, installing and tensioning»(ref-255004-S41744530922007052300000)

3 - Coolant pump

  1. Check for ease of movement
  2. If damaged or leaking replace completely
  3. Removing and installing, refer to «Coolant pump, removing and installing»(ref-255004-S37187627982007052300000)

4 - O-ring

  1. Replace

5 - Coolant thermostat

  1. Checking: Heat up thermostat in water
  2. Opening begins approx. 87 ° C
  3. Ends approx. 102 ° C
  4. Opening lift min. 7 mm

6 - O-ring

  1. Replace

7 - Connecting piece

8 - To heat exchanger

  1. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

9 - O-ring

  1. Replace

10 - Connector

  1. 4-pin

11 - Engine Coolant Temperature (ECT) Sensor G62

  1. With Engine Coolant Temperature (ECT) Gauge Sensor G2
  2. For engine control module
  3. If necessary, release pressure in cooling system before removing
  4. Checking

12 - Retaining clip

  1. Check for secure seat

13 - Upper coolant hose

  1. Secured to radiator with a retaining clip
  2. Ensure seated tightly
  3. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

14 - Lower coolant hose

  1. Secured to radiator with a retaining clip
  2. Ensure seated tightly
  3. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

15 - Oil cooler

16 - From heat exchanger

  1. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

17 - Lower coolant line

  1. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

18 - 10 Nm

19 - Cap

  1. Check using cooling system tester V.A.G 1274 and adapter V.A.G 1274/9
  2. Test pressure 1.4 to 1.6 bar positive pressure

20 - Seal

  1. Replace if damaged

21 - 10 Nm

22 - Expansion tank

  1. Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapter V.A.G 1274/8.

23 - To turbocharger

  1. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

24 - 15 Nm

25 - To top coolant hose

  1. Only engine code AWP with automatic transmission
  2. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)

26 - After-run coolant pump V51

  1. Only engine code AWP with automatic transmission
  2. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)
  3. Checking, refer to «After-Run Coolant Pump V51 , checking»(ref-255004-S30608988462007052300000)

27 - From turbocharger

  1. Only engine code AWP with automatic transmission
  2. Coolant hose connection diagram, refer to «Coolant hose connection diagram»(ref-255004-S22849353742007052300000)