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1.9l - Cooling System - Engine Code(s): Alh (hatchback) Volkswagen New Beetle A4

Cooling Fan 11 illustrations ~1637 words

COOLING SYSTEM COMPONENTS

Note. As the engine warms up, cooling system pressure also increases. If necessary, release pressure before starting repair work. Hoses are secured with spring clips. When performing repairs, only use spring clips. pliers VAG 1921 are recommended for installing spring clips. When installing coolant hoses, route them stress-free, so they do not come into contact with other components (observe markings on coolant connections and hoses).

Perform cooling system leakage test with cooling system tester VAG 1274 and adapter VAG 1274/9.

COOLANT, DRAINING AND FILLING

Special tools and workshop equipment required

  1. Drip tray VAG 1306 for VAG 1202 A
  2. Hose clip pliers VAG 1921
  3. Anti-freeze tester

Draining

Remove engine cover.

Remove cap from coolant expansion tank.

Remove insulation tray center and left: Description and Operation

Unscrew drain plug to drain coolant from radiator -arrow-.

Scheme 33

Scheme 33
Scheme 33

To drain coolant from engine also remove coolant hose from oil cooler -arrow-.

Scheme 34

Scheme 34
Scheme 34

Note. Observe proper disposal regulations!

Filling

Note. Only use coolant additive G 12 in accordance with TLVW 774 D. Identifying color: red. On no account must G 12 be mixed with other coolant additives! If the fluid in expansion tank is brown, G 12 has been mixed with other coolant. In this case the coolant must be changed. G 12 and coolant additives marked "In accordance with TLVW 774 D" prevent frost and corrosion damage, scaling and also raise boiling point of coolant. For this reason the system must be filled all year round with frost and corrosion protection additives. Particularly in countries with tropical climates, the coolant due to the higher boiling point improves engine reliability when heavily loaded. Protected against frost to about -25 °C (in arctic climatic countries to about -35 °C). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The anti-freeze ratio must be at least 40%. Use only clean water when mixing the coolant. If for climatic reasons a greater frost protection is required, the amount of G 12 can be increased, but only up to 60% (frost protection to about -40°C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced. If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.

Recommended mixture ratios

Frost protection toAntifreeze amountG 12, item 1Clean Water, item 1
25°C -35°C40% 50%2.4 ltr. 3.0 ltr.3.6 ltr. 3.0 ltr.
  1. The quantity of coolant can vary depending upon the vehicle equipment.

Close drain plug for coolant.

Fill with coolant up to MAX. mark on expansion tank.

Scheme 35

Scheme 35
Scheme 35

Install coolant expansion tank cap.

Run engine until radiator coolant fan comes on.

Check coolant level and top off if necessary. When engine is at normal operating temperature, coolant level must be on MAX. mark. When engine is cold, coolant level can be between MIN. and MAX. marks.

A/C SYSTEM REMOVAL, ADDITIONAL INFORMATION

CAUTIONDo NOT open the A/C refrigerant circuit.

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

Remove retaining clamp(s) from refrigerant lines.

Before removing lock support, fasten radiator to body

To remove radiator, fasten condenser to body.

Scheme 36

Scheme 36: COOLING SYSTEM COMPONENTS ASSEMBLY OVERVIEW, BODY SIDE
Scheme 36: COOLING SYSTEM COMPONENTS ASSEMBLY OVERVIEW, BODY SIDE
  1. Radiator Removing and installing «RADIATOR»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback__radiator) After replacing, replace entire engine coolant
  2. O-ring Always replace
  3. Coolant hose, upper Attached to radiator with clip Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  4. Retaining clip Make sure it is securely seated
  5. Engine Coolant Temperature (ECT) sensor -G62- Checking: «ENGINE COOLANT TEMPERATURE SENSOR, CHECKING»(/volkswagen/new-beetle/a4-1997-2005/remont/fuel-system/#19l-diesel-fuel-injection-engine-codes-alh-hatchback-as-of-062007__engine-coolant-temperature-sensor-checking) With Engine Coolant Temperature (ECT) sensor -G2
  6. 4 Nm
  7. Cap Check using tester VAG 1274 and adapter VAG 1274/8 Test pressure 1.4 to 1.6 bar
  8. 2 Nm
  9. Coolant expansion tank Perform cooling system leak check using tester VAG 1274 with adapter VAG 1274/9
  10. Connector
  11. To cylinder head Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  12. Air ducting
  13. 10 Nm
  14. Auxiliary fan Optional equipment
  15. Fan ring For auxiliary fan
  16. Retaining clip Make sure it is seated securely
  17. Fan ring
  18. Coolant fan
  19. Bracket For coolant fan connector
  20. Coolant hose, lower Attached to radiator with clip Coolant hose connection diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  21. Coolant Fan Control (FC) thermal switch -F18- 35 Nm For electric fan Switching temperatures: Stage 1 ON: 92 to 97 °C OFF: 84 to 91 °C Stage 2 ON: 99 to 105 °C OFF: 91 to 98 °C
  22. Bracket For radiator
  23. Bracket For radiator Note installed position

Scheme 37

Scheme 37: COOLING SYSTEM COMPONENTS ASSEMBLY OVERVIEW, ENGINE SIDE
Scheme 37: COOLING SYSTEM COMPONENTS ASSEMBLY OVERVIEW, ENGINE SIDE
  1. 25 Nm
  2. Coolant pump Check arm for ease of movement Note installation position Removing and installing: «COOLANT PUMP»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback__coolant-pump) If damaged and leaking replace complete assembly
  3. O-ring Always replace
  4. EGR cooler
  5. To expansion tank Coolant hose connection diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  6. Coolant hose, upper Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  7. To cylinder head Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  8. To heat exchanger Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  9. From heat exchanger Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  10. Coolant pipe Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  11. 10 Nm
  12. To expansion tank, lower Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  13. EGR cooler supply Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  14. Connection With Glow plugs (coolant -Q7- for auxiliary heater
  15. To top of radiator Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback) Clipped to bulkhead
  16. O-ring Make sure it is seated securely Always replace
  17. To bottom of radiator Coolant hose connections, diagram «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback)
  18. Connection For thermostat
  19. Coolant thermostat Removing and installing «THERMOSTAT»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback__thermostat) Observe installed position «THERMOSTAT»(/volkswagen/new-beetle/a4-1997-2005/remont/cooling-fan/#19l-cooling-system-engine-codes-alh-hatchback__thermostat) Checking: heat-up thermostat in water Opening starts at 85 °C approx. Ends approx. 105 °C Opening lift 7 mm minimum
  20. Oil cooler Removing and installing: refer to "Oil Cooler" under «OIL FILTER ASSEMBLY OVERVIEW»(/volkswagen/new-beetle/a4-1997-2005/remont/lubrication-system/#19l-lubrication-engine-codes-alh-hatchback)

Scheme 38

Scheme 38: COOLANT HOSE CONNECTION DIAGRAM
Scheme 38: COOLANT HOSE CONNECTION DIAGRAM
  1. Radiator
  2. Oil cooler
  3. Coolant pump
  4. Engine block
  5. Expansion tank
  6. Intake manifold
  7. EGR cooler
  8. Heating system heat exchanger
  9. Coolant pipe
  10. Transmission cooler Vehicles with automatic transmission
  11. Coolant hose, upper
  12. Coolant hose, lower

RADIATOR

Special tools and workshop equipment required

  1. Drip tray VAG 1306 for VAG 1202 A
  2. Torque wrench: 5 to 50 Nm VAG 1331
  3. Hose clip pliers VAG 1921
  4. Anti-freeze tester

Removing

Remove front panel: Description and Operation

Disconnect coolant hoses from radiator.

Disconnect connectors from thermo-switch.

Remove ribbed belt tensioner RIBBED BELT TENSIONER .

Remove radiator mounting bolts and take out radiator.

Note. Vehicles with A/C: Observe additional information and removal work. A/C SYSTEM REMOVAL, ADDITIONAL INFORMATION

Installing

Installation is performed in the reverse order of the removal procedure. Note the following during installation

Engine coolant, filling COOLANT, DRAINING AND FILLING

COOLANT PUMP

Special tools and workshop equipment required

  1. Drip tray VAG 1306 for VAG 1202 A
  2. Torque wrench: 5 to 50 Nm VAG 1331
  3. Hose clip pliers VAG 1921
  4. Anti-freeze tester

Removing

Note. Always replace seals and gaskets. Lower part of the toothed belt guard need not be removed. Toothed belt should be left in position on the crankshaft sprocket. Cover toothed belt with a cloth to protect it from coolant before removing coolant pump.

Remove ribbed belt RIBBED BELT TENSIONER

Disconnect fuel supply and return lines at fuel filter.

Remove connector hose between charge air cooler and intake manifold CHARGE AIR COOLER ASSEMBLY OVERVIEW

Remove fuel filter with bracket FUEL FILTER ASSEMBLY OVERVIEW

Remove belt guard upper and middle sections TOOTHED BELT GUARD ASSEMBLY OVERVIEW

Remove V-belt from camshaft sprocket, injection pump sprocket and coolant pump sprocket TOOTHED BELT

Unscrew mounting bolt -1- from pulley -2- and press downward approx. 30 mm.

Scheme 39

Scheme 39
Scheme 39

Unscrew mounting bolts -3- from coolant pump and carefully remove coolant pump -4- between engine bracket and toothed belt guard.

Installing

Installation is performed in the reverse order of the removal procedure. Note the following during installation

Moisten new O-ring -3- with clean engine coolant.

Insert coolant pump -4- into engine block and tighten mounting bolts -5- to 15 Nm.

Note. Coolant pump plug points downward.

Install pulley -2- and tighten mounting bolt -1- (replace). Tightening torque: 40 Nm plus 90° (1/4 turn).

Install and tighten toothed belt TOOTHED BELT .

Install fuel filter with bracket.

Disconnect fuel supply and return lines at fuel filter.

Install ribbed belt. RIBBED BELT TENSIONER .

Install connecting hose between charge air cooler and intake hose CHARGE AIR COOLER ASSEMBLY OVERVIEW .

Fill engine with coolant COOLANT, DRAINING AND FILLING .

THERMOSTAT

Special tools and workshop equipment required

  1. Drip tray VAG 1306 for VAG 1202 A
  2. Torque wrench: 5 to 50 Nm VAG 1331
  3. Hose clip pliers VAG 1921
  4. Anti-freeze tester

Removing

Note. Always replace seals and gaskets.

Remove coolant hose from connection -2-.

Scheme 40

Scheme 40
Scheme 40

Unscrew mounting bolts -1- of connection -2- and remove connection -2- along with thermostat -4-.

Turn thermostat -4- 1 / 4 turn (90 °) to left and remove from connection -2-.

Installing

Installation is performed in the reverse order. Note the following during installation

Moisten new O-ring -3- with coolant.

Insert thermostat -4- in connection -2- and turn 1 / 4 turn (90 °) to right.

Note. The brace on the thermostat must be almost vertical.

Install thermostat -4- into engine block.

Tighten mounting bolt -1- to 15 Nm.

Fill engine with coolant COOLANT, DRAINING AND FILLING .

Scheme 41

Scheme 41: SPECIAL TOOLS
Scheme 41: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Drip tray VAG 1306 for VAG 1202 A
  2. Torque wrench: 5 to 50 Nm VAG 1331
  3. Hose clip pliers VAG 1921

Special tools and workshop equipment required

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43
  1. Drip tray VAG 1306 for VAG 1202 A
  2. Hose clip pliers VAG 1921

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