2.0L - Cooling System - Engine Code(s): Cbfa & Ccta (Sedan) (A5 Platform): Maintenance Volkswagen Jetta V

DRAINING AND FILLING

Special tools and workshop equipment required

1. Refractometer T10007
2. Drip Tray for VAS 6100 VAS 6208 or V.A.G 1306
3. Hose Clip Pliers VAS 6362
4. Cooling System Charge Unit VAS 6096
5. Adapter V.A.G 1274/8

Draining

Open the coolant expansion tank cap.

Remove the noise insulation. Refer to Description and Operation .

Disconnect the charge air hose by lifting the clamp -1- and loosening the clamp -2-.

Scheme 149

Seal off the connections on the charge air cooler with a clean cloth.

Note. Collect leaking coolant in a clean container for disposal or reuse.

Place the drip tray for VAS 6100 VAS 6208 or V.A.G 1306 under the engine.

Remove the lower coolant hose -1- from the radiator and let the coolant drain.

Scheme 150

Remove the lower coolant hose from the after-run coolant pump -V51- -arrow- and allow the coolant to drain.

Scheme 151

Filling

Note. The water portion of the coolant influences the effectiveness of the coolant. Volkswagen has decided to define the water quality used in the cooling system based on the different mixtures and country and regional requirements. For this reason, we recommend using distilled water for older models when adding coolant or filling coolant for the first time. On newer models (from MY 10), distilled water is required.

Note. Only use G 12 Plus-Plus in accordance with TL VW 774 G as a coolant. Coolant with the note "conforming to TL VW 774 G" prevent frost and corrosion damage, scaling and also raise boiling point of coolant. 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 portion must be at least 40%. If greater frost protection is required for climatic reasons, the amount of coolant can be increased, but only up to 60% (frost protection down to approximately -40 °C (-40 °F)), otherwise frost protection and cooling effectiveness will be 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

Connect the lower coolant hose -1- to the radiator.

Connect the coolant hose to the after-run coolant pump -arrow-.

Install the charge air hose -1 and 2-.

Install the noise insulation. Refer to Description and Operation .

Using 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 cooling system filler unit VAS 6096.

Without the Cooling System Charge Unit VAS 6096

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

Scheme 152

Install the expansion tank cap.

Turn off the Air Conditioning (A/C) and the heater.

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.

Close the expansion tank and check the coolant level. Fill the coolant when the engine is cold, if necessary.

1. With the engine at operating temperature, the coolant level must be at the top mark of the hatched area -arrow-.
2. With the engine cold, the coolant level should be located approximately in the center of the hatched area.

Scheme 153

1. Radiator
2. After-Run Coolant Pump -V51
3. Coolant Pump
4. Coolant Thermostat
5. Engine Oil Cooler
6. Cylinder Head and Cylinder Block
7. Turbocharger
8. Coolant Expansion Tank With the cap. Checking the pressure valve in the cap. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-479585-S29365391702012061300000) .
9. to the Auxiliary Heater Not available in the US/Canadian market.
10. from the Auxiliary Heater Not available in the US/Canadian market.
11. Heater Core
12. Coolant Connection

Scheme 154

1. Radiator
2. After-Run Coolant Pump -V51
3. Coolant Thermostat
4. Coolant Pump
5. Engine Oil Cooler
6. Cylinder Head and Cylinder Block
7. Turbocharger
8. Coolant Expansion Tank With the cap. Checking the pressure valve in the cap. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(ref-479585-S29365391702012061300000) .
9. to the Auxiliary Heater Not available in the US/Canadian market.
10. from the Auxiliary Heater Not available in the US/Canadian market.
11. Heater Core
12. Transmission Oil Cooler
13. Coolant Connection
14. Thermostat for the Transmission Oil Cooler On some vehicles, the thermostat is located on the outflow side of the transmission oil cooler, refer to "Transmission Oil Cooler" in item: 12 .

Scheme 155

1. Coolant Fan -V7- Removing and installing, refer to «COOLANT FAN AND COOLANT FAN 2»(ref-479585-S22801804642012061300000).
2. Nut 10 Nm
3. Fan Shroud Removing and installing, refer to «FAN SHROUD»(ref-479585-S40479117792012061300000).
4. Lower Coolant Hose To the connection for the thermostat.
5. Retaining Clip Make sure it is secure.
6. Engine Coolant Temperature Sensor on Radiator -G83- With a O-ring. Always replace the O-ring.
7. O-ring Replace if damaged.
8. Upper Coolant Hose From the coolant pump.
9. O-ring Replace if damaged.
10. Bolt 5 Nm To the charge air cooler.
11. Radiator Removing and installing, refer to «RADIATOR»(ref-479585-S07818165312012061300000). After replacing, replace the entire amount of coolant. Refer to «DRAINING AND FILLING»(ref-479585-S28001148572012061300000). With engine code CBFA: Radiator identification sensor (Scheme 156)
12. Nut 10 Nm
13. Bolt 5 Nm To the radiator.
14. Coolant Fan 2 -V177- Removing and installing, refer to «COOLANT FAN AND COOLANT FAN 2»(ref-479585-S22801804642012061300000).

Scheme 156

Arrow- indicates the direction of travel

A - Radiator

B - Radiator identification sensor

Note. The sensor can be replaced with the radiator.

Scheme 157

1. Bolt 9 Nm Tightening sequence and specification. (Scheme 158)
2. O-ring Always replace. Lubricate with coolant.
3. Connection
4. Retaining Clip Only with the inserted version. Make sure it is secure.
5. Bolt 4 Nm Only with the threaded version.
6. Retaining Plate Only with the threaded version.
7. Engine Coolant Temperature Sensor -G62- Removing and installing, refer to «Engine Coolant Temperature Sensor -G62»(ref-479585-S35653533162012061300000).
8. O-ring Always replace.
9. Coolant Pump Removing and installing, refer to «COOLANT PUMP»(ref-479585-S22263074172012061300000). On a new coolant pump, remove the protective cap.
10. Gasket Always replace.
11. Centering Pin Quantity: 2
12. Toothed Belt For the coolant pump. Removing and installing, refer to «COOLANT PUMP TOOTHED BELT»(ref-479585-S06261801302012061300000).
13. Toothed Belt Guard
14. Bolt 9 Nm
15. Bolt 17 Nm Always replace. Has left hand threads
16. Toothed Belt Drive Gear Note the installed position: The collar on the drive gear faces the transmission.
17. Seal Removing and installing, refer to «COOLANT PUMP DRIVE GEAR SEAL, REPLACING»(ref-479585-S31542776342012061300000).
18. Balance Shaft
19. Coolant Thermostat The coolant thermostat can be checked in "Guided Fault Finding" under "Function and Component Selection". Removing and installing, refer to «COOLANT THERMOSTAT»(ref-479585-S08206710522012061300000).
20. Centering Pin
21. O-ring Always replace.
22. Connecting Piece
23. Bolt 9 Nm

Scheme 158

Special tools and workshop equipment required

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

Procedure

Tighten the coolant pump bolts in sequence -1 through 5-.

Tightening specification: 9 Nm