2.5l - Cooling System - Engine Code(s): Bpr & Bps (hatchback) Volkswagen New Beetle A4 рестайлинг

GENERAL REPAIR INFORMATION

Note. When the engine is warm the cooling system is under pressure. If necessary release the pressure before beginning repair work. Secure all hose connections with hose clamps. The hose clip pliers VAG 1921 or hose clip pliers VAS 6340 are recommended for installing spring clamps. Always replace gaskets and seals. Arrows on coolant pipes and coolant hoses must line up across from each other.

DRAINING AND FILLING

Special tools and workshop equipment required

1. Refractometer T10007
2. Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208
3. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340
4. Cooling system charge unit VAS 6096
5. Adapter VAG 1274/8

Draining

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

Open the coolant expansion tank cap.

Remove the noise insulation. Refer to Description and Operation .

Place the VAG 1306 or VAS 6208 underneath.

Loosen the drain plug -arrow- to drain the coolant from radiator.

Scheme 1

Filling

Note. On vehicles from Model Year (MY) 2008, only use coolant additive G12 plus-plus that conforms to "TL VW 774 G". On vehicles through MY 2007, coolant additive G12 plus that conforms to "TL VW 774 F" and G12 plus-plus that conforms to "TL VW 774 G" can be used. G12 plus-plus may be mixed with the previous coolant additive G12 plus. Both are colored purple. Coolant additives marked with "Conforms to TL VW 774 G" or "Conforms to TL VW 774 F" prevent freezing and corrosion damage and scaling and they increase the boiling point. For this reason the system must be filled all year round with frost and corrosion protection additives. 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 to about -25 °C (-13 °F) (in arctic climatic countries to about -35 °C (-31 °F)). The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The coolant additive portion must be at least 40%. If for climatic reasons a greater frost protection is required, the amount of coolant additive of can be increased, but only up to 60% (frost protection to about -40 °C (-40 °F), as otherwise frost protection is reduced again and cooling effectiveness is also reduced. Refractometer T10007 is recommended for determining freeze protection density. If radiator, heat exchanger, cylinder head or cylinder head gasket is replaced, do not reuse old coolant.

Recommended Mixture Ratios

Tighten the drain plug in radiator -arrow-.

Install the noise insulation. Refer to Description and Operation .

Fill using VAS 6096.

Install the VAG 1274/8 onto the expansion tank.

Fill the coolant circuit using the VAS 6096. Refer to the operating instructions for cooling system filler unit VAS 6096.

Filling without VAS 6096

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

Scheme 2

Install the expansion tank cap.

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

Start the engine and maintain an engine speed of about 2000 RPM for approximately 3 minutes.

Let the engine run until the fan starts up.

Check the coolant level and top off as necessary.

1. With the engine at operating temperature, coolant level must lie at the top marking 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 3

1. Radiator Removal and installation, refer to «RADIATOR»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__radiator) . Replace the coolant after replacing.
2. Oil Cooler
3. Coolant Pump and Coolant Thermostat Coolant pump removal and installation, refer to «COOLANT PUMP»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__coolant-pump) . Thermostat removal and installation, refer to «COOLANT THERMOSTAT»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__coolant-thermostat) . Checking coolant thermostat -item 16- «COOLING SYSTEM COMPONENTS, ENGINE SIDE»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
4. Cylinder Head/Cylinder Block Replace the coolant after replacing.
5. Expansion Tank With the sealing cap Checking pressure relief valve in cap. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
6. Intake Manifold
7. Throttle Valve Control Module -J338- Connection only for coolant heated throttle valve control module.
8. Quick Release Coupling
9. Heater Core Replace coolant after replacing.
10. Transmission Oil Cooler Only for vehicles with a automatic transmission.
11. Coolant Line
12. Coolant Distribution Housing

Part 1

Part 2, refer to COOLING SYSTEM COMPONENTS, ENGINE SIDE .

Scheme 4

1. Cylinder Block
2. Oil Cooler
3. Bolt, 25 Nm
4. Bolt/Nut, 10 Nm
5. to Heater Core, Bottom
6. Retaining Clip Check clip for secure seating.
7. O-ring Replace
8. Front Coolant Line
9. O-ring Replace
10. Coolant Line
11. Connecting Hose
12. Connecting Piece
13. to Radiator, Bottom
14. Bolt, 5 Nm
15. O-ring Replace
16. Coolant Thermostat Removal and installation, refer to «COOLANT THERMOSTAT»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__coolant-thermostat) . Note the installed position: Valve must be at top Checking, coolant thermostat installed: Checking, coolant thermostat removed: Heat up thermostat in water. Starts to open: approximately 87 °C (188.6 °F) Opening ends: approximately 102 °C (215.6 °F) opening distance: minimum 7 millimeter (mm)
17. Seal Replace
18. Bolt, 25 Nm
19. Coolant Thermostat Housing
20. Seal Replace
21. Accessory Bracket
22. Bolt, 10 Nm
23. Coolant Pump With integrated silicone seal for the cylinder block seal. Removal and installation, refer to «COOLANT PUMP»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__coolant-pump) .
24. Connecting Hose
25. to Expansion Tank, Bottom

Part 2

Part 1, refer to COOLING SYSTEM COMPONENTS, ENGINE SIDE .

Scheme 5

1. Coolant Connection Pressed in the cylinder head. Clean before installing coolant distribution housing -item 17-. -- If necessary, remove coolant deposits using a copper wire brush or fine sandpaper (minimum 100 grit). If the connection is worn, replace it using locking fluid D 000600 A2.
2. Circlip
3. Seal Replace after removing the coolant distribution housing -item 17-.
4. to Expansion Tank, Top
5. Rear Coolant Pipe
6. Bolt/Nut, 10 Nm
7. to Heater Core, Top
8. Supply Hose
9. Bypass Thermostat Only for vehicles with a automatic transmission. Assembly overview (Scheme 6) Bypass Thermostat, Checking, refer to «COOLING SYSTEM COMPONENTS, ENGINE SIDE»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback).
10. to Transmission Oil Cooler Only for vehicles with a automatic transmission.
11. Supply Hose
12. from Heater Core, Bottom
13. from Transmission Oil Cooler Only for vehicles with a automatic transmission.
14. Return Hose
15. Coolant Line Bolted to the coolant regulator housing -item 17-.
16. to Coolant Thermostat Housing
17. Coolant Distribution Housing
18. Supply Hose
19. to Top of Radiator
20. Coolant Hoses Only for the throttle valve control module heated by coolant.
21. Throttle Valve Control Module -J338- Connection only for coolant heated throttle valve control module.
22. Engine Coolant Temperature (ECT) Sensor -G62
23. O-ring Replace
24. Retaining Clip Check clip for secure seating.

Scheme 6

1 - Spring bracket

2 - Lower part of housing

Note the installed position: The arrow points toward the transmission oil cooler.

3 - Operating element

4 - Spring

5 - O-ring

6 - Upper part of housing

Bypass Thermostat, Checking

Remove the operating element -3- and heat in hot water.

Starts to open: approximately 75 °C (167 °F)

Opening end: approximately 85 °C (185 °F)

Opens: approximately 5 millimeter (mm)

Scheme 7

1. Radiator Removal and installation, refer to «RADIATOR»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__radiator) . After replacing, replace the entire amount of coolant.
2. Fan Shroud with Coolant Fan -V7- Removal and installation, refer to «FAN SHROUD WITH COOLANT FAN»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__fan-shroud-with-coolant-fan) .
3. O-ring Replace if damaged.
4. Upper Coolant Hose Secured to the radiator with a retaining clip. Ensure the hose is securely seated. Coolant hose connection diagram, refer to «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
5. Connector
6. Cap Checking, refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
7. Bolt, 2 Nm
8. from Rear Coolant Pipe See Rear Coolant Pipe-item 5- in «COOLING SYSTEM COMPONENTS, ENGINE SIDE»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
9. Expansion Tank Cooling system, checking for leaks. Refer to «COOLING SYSTEM, CHECKING FOR LEAKS»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
10. to Coolant Thermostat Housing See Coolant Thermostat Housing-item 19- in «COOLING SYSTEM COMPONENTS, ENGINE SIDE»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
11. Coolant Fan Control (FC) Control Module -J293- Forms a unit with coolant fan motor -item 17-.
12. Bolt, 5 Nm
13. Bolt
14. Fan Wheel
15. Fan Ring
16. Cover
17. Coolant Fan Motor Forms a unit with the coolant FC control module -item 11-.
18. Bolt, 5 Nm
19. Washer
20. Bolt
21. Connector
22. Bolt, 5 Nm
23. Lower Coolant Hose Secured to the radiator with a retaining clip. Ensure the hose is securely seated. Coolant hose connection diagram, refer to «COOLANT HOSE CONNECTION DIAGRAM»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
24. Bracket For the radiator. Note the installed position.
25. Bolt, 5 Nm

FASTENER TIGHTENING SPECIFICATIONS

CHECKING WITH VAG 1274

Special tools and workshop equipment required

1. Cooling system tester VAG 1274
2. Adapter VAG 1274/8
3. Adapter VAG 1274/9

Conditions

1. Engine at operating temperature

Sequence

Open the coolant expansion tank cap.

Install the VAG 1274/8 and the VAG 1274 to the expansion tank.

Generate a positive pressure of approximately 1.0 bar using the VAG 1274.

If the pressure drops

Search for leaking areas and repair the malfunction.

Pressure Relief Valve in Cap, Checking

Install the VAG 1274/9 and the VAG 1274 to the cap.

Scheme 8

Operate the VAG 1274.

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

If the pressure relief valve opens too early or too late

Replace the cap.

CHECKING WITH VAG 1274B

Special tools and workshop equipment required

1. Cooling system tester VAG 1274B
2. Adapter VAG 1274/8
3. Adapter VAG 1274/9

Conditions

1. Engine at operating temperature.

Sequence

Open the coolant expansion tank cap.

Install the VAG 1274/8 onto the expansion tank.

Clamp the VAG 1274B/1 in the VAG 1274/8.

Connect the VAG 1274B/1 to the VAG 1274B using the connecting hose.

Scheme 9

Generate a positive pressure of approximately 1.0 bar using the VAG 1274B.

If the pressure drops

Search for leaking areas and repair the malfunction.

Pressure Relief Valve in Cap, Checking

Install the cap in the VAG 1274/9.

Clamp the VAG 1274B/1 in the VAG 1274/9.

Connect the VAG 1274B/1 to the VAG 1274B using the connecting hose.

Scheme 10

Actuate the VAG 1274B.

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

If the pressure relief valve opens too early or too late

Replace the cap.

COOLANT FAN, CHECKING

Special tools and workshop equipment required

1. Connector test set VAG 1594 A
2. Wiring diagram

Prerequisites

Scheme 11

1. Main fuses must be OK.
2. Coolant Fan Control (FC) Thermal Switch -F18- OK.

Sequence

Disconnect the connector for the coolant FC thermal switch.

Bridge terminals 1 and 2 of connector with adapter cables from VAG 1594A.

Stage 1 of coolant fan -V7- must start up.

Switch on the ignition.

Bridge terminals 2 and 3 of connector with adapter cables from VAG 1594A.

Stage 2 of coolant fan must start up.

If 1st or 2nd speeds of fans do not run

Locate and repair open circuit in wiring using wiring diagram. Refer to SYSTEM WIRING INFORMATION.

If no fault is detected in the wiring

Replace the coolant fan.

COOLANT PUMP

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Torque wrench (40-200 Nm) VAG 1332
3. Engine and transmission jack VAG 1383A
4. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340
5. Step ladder VAS 5085
6. Engine holder bracket T03000
7. Hose clamps up to 25 mm dia. 3094
8. Old oil collecting and extracting device VAG 1782
9. Adapter set for engine and transmission support VW 540/1 A
10. M8 x 100 bolt
11. Cable tie

Note. To perform this procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti-theft code beforehand. The engine is removed downward together with the transmission. All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.

Removing

Remove the engine cover.

Remove the intake hose -1- and connector -2- from the Mass Air Flow (MAF) sensor.

Scheme 12

Disconnect the hose -3- from the air filter housing.

Remove the bolts -4 and 6- and remove the air filter housing.

Remove the battery. Refer to Removal and Installation .

Remove the battery holder bolts -arrows- and holder.

Scheme 13

Remove the ribbed belt. Refer to RIBBED BELT .

Remove the rear bolt -arrow- for the engine mount through the wheel housing.

Scheme 14

Remove the pendulum support bolts -arrows-.

Scheme 15

Drain the coolant. Refer to DRAINING AND FILLING .

Bring the lock carrier into service position. Refer to Removal and Installation .

Support the lock carrier using a sleeve -B-, 80 millimeters (mm) in length, for example, from VW 540/1 A and a M8 x 100 bolt -A-.

Scheme 16

Empty the power steering reservoir using VAG 1782 and remove it.

Remove the bracket nuts -2- for the power steering reservoir.

Scheme 17

Remove the nut -1- from the bracket. To do so, remove the right main head lamp. Refer to Removal and Installation .

Disconnect the intake line from the power steering pump. Seal the pump and line with clean plugs.

Remove the nut -arrow- for the intake line -A- at the engine mount. Remove the intake line.

Scheme 18

Only slightly loosen the bolts for the engine and transmission mounts at the subframe (less than 1 rotation).

Install the T03000 as follows

Scheme 19

1. Remove pin T03000/1 from T03000.
2. Install the T03000 to the cylinder block with pin -3- and tighten the bolts -1 and 2- hand tight.
3. Then install pin T03000/1 and tighten to 20 Nm.
4. Then tighten bolts -1 and 2- to 25 Nm.

Place the T03000 on the VAG 1383A and lift the engine/transmission assembly slightly.

Remove the engine mount bolts -arrows- from above and remove.

Scheme 20

Note. Use VAS 5085 to remove the bolts.

Remove both front bolts from the holding fixture.

Remove the transmission mount bolts -arrows- from above.

Scheme 21

Carefully lower the engine with transmission only as far downward -arrow 2- until pin -4- of transmission mount bracket can be slid toward the left -arrow 3- out from under the transmission mount.

Scheme 22

Slide the engine/transmission assembly until it stops at left longitudinal member.

Rotate the pulley so that arrow -A- (relative to engine axis) points upward vertically.

Scheme 23

Remove the coolant pump bolts -arrows-.

Pull the coolant pump -A- out of the cylinder block.

Scheme 24

Guide the coolant pump -A- through between the longitudinal member and cylinder block and remove it.

Installing

Installation is performed in the reverse order of removal. When doing this note the following

Note the installed position of coolant pump before installing.

Rotate the pulley so that the arrow -A- (relative to engine axis) points upward vertically. Holes in the pulley must align opposite the bolts -arrows-.

First, firmly bolt the engine mount to the engine, then align the engine/transmission assembly free of tension via a shaking motion and tighten the bolts to the subframe.

Note. Tightening specifications for the engine and transmission mounts. Refer to FASTENER TIGHTENING SPECIFICATIONS .

Install the lock carrier. Refer to Description and Operation .

Install the bracket for the reservoir and power steering line. Refer to Specifications .

Install the ribbed belt. Refer to RIBBED BELT .

Install the battery. Refer to Removal and Installation .

Fill with coolant. Refer to DRAINING AND FILLING .

Install noise insulation. Refer to Description and Operation .

Fill the power steering system with hydraulic oil. Refer to General Information .

Install the battery. Refer to Removal and Installation .

Tightening Specifications

COOLANT THERMOSTAT

Special tools and workshop equipment required

1. Refractometer T10007
2. Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208
3. Torque wrench (5-50 Nm) VAG 1331
4. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the intake manifold. Refer to INTAKE MANIFOLD .

Install the guide tube for the oil dipstick into the cylinder block again and secure it tightly so that no escaping coolant can run into the engine.

Place a suitable container under the coolant thermostat housing to catch coolant flowing out.

Remove the bolts -arrows-, disconnect the connecting piece -A- and remove the thermostat.

Scheme 25

Installing

Installation is performed in the reverse order of removal. When doing this note the following

Scheme 26

1. Replace the seal -item 17- in «COOLING SYSTEM COMPONENTS, ENGINE SIDE»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) and O-ring -item 15- in «COOLING SYSTEM COMPONENTS, ENGINE SIDE»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback) .
2. Note the installed position of the thermostat -1-. Valve -2- must point upward.
3. Fill with coolant. Refer to «DRAINING AND FILLING»(/volkswagen/new-beetle/a4-2005-2011/remont/cooling-fan/#25l-cooling-system-engine-codes-bpr-bps-hatchback__draining-and-filling) .

Tightening Specifications

FAN SHROUD WITH COOLANT FAN

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Bring the lock carrier into service position. Refer to Description and Operation .

Support the lock carrier using a sleeve -B-, 80 millimeters (mm) in length, for example, from VW 540/1A and a M8 x 100 bolt -A-.

Disconnect electrical connector -A-.

Scheme 27

Remove the bolts -arrows- for the fan shroud.

Scheme 28

Remove the fan shroud.

Installing

Installation is performed in the reverse order of removal. When doing this note the following

Tightening Specifications

RADIATOR

Refractometer T10007

Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208

Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340

Cooling system charge unit VAS 6096

Adapter VAG 1274/8

Removing

Drain the coolant. Refer to DRAINING AND FILLING .

Remove the fan shroud with the coolant fan -V7-. Refer to FAN SHROUD WITH COOLANT FAN .

Vehicles with Air Conditioning (A/C)

Remove the bolt -arrow- for the refrigerant line -A-.

Scheme 29

Continuation for All Vehicles

Remove the bolts -arrows- from the radiator.

Scheme 30

Vehicles with A/C

Remove the bolts -arrows- for the condenser on the left and right sides of the radiator.

Scheme 31

To remove the radiator, secure the condenser to the lock carrier.

Continuation for All Vehicles

Remove the radiator downward.

Installing

Installation is performed in the reverse order of removal, noting the following

The coolant must be replaced if a new radiator was installed.

Fill with coolant. Refer to DRAINING AND FILLING .

Tightening Specifications

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

1. Adapter set for engine and transmission support VW 540/1 A
2. Cooling system tester VAG 1274
3. Adapter VAG 1274/9
4. Cooling system tester VAG 1274B
5. Adapter VAG 1274/9
6. Connector test set VAG 1594 A
7. Hose clamps up to 25 mm dia. 3094
8. Old oil collecting and extracting device VAG 1782

Scheme 37

Special tools and workshop equipment required

1. Refractometer T10007
2. Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208
3. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340
4. Cooling system charge unit VAS 6096
5. Adapter VAG 1274/8

Scheme 38

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Torque wrench (40-200 Nm) VAG 1332
3. Engine and transmission jack VAG 1383A
4. Spring type clip pliers VAS 5024A or hose clip pliers VAS 6340
5. Step ladder VAS 5085
6. Engine holder bracket T03000

See also:
• Description and Operation
• Removal and Installation
• RIBBED BELT
• Removal and Installation
• FASTENER TIGHTENING SPECIFICATIONS
• Specifications
• INTAKE MANIFOLD
• RADIATOR
• COOLANT PUMP
• COOLANT THERMOSTAT
• COOLING SYSTEM COMPONENTS, ENGINE SIDE
• FAN SHROUD WITH COOLANT FAN
• DRAINING AND FILLING