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Home/Volkswagen/Passat/Volkswagen Passat B5 (1996-2001)/Repair manual/1.8L - Engine Mechanical, Fuel Injection Ignition, Engine Code(s): Aeb, Atw/Cooling system components
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Cooling system components Volkswagen Passat B5

1.8L - Engine Mechanical, Fuel Injection Ignition, Engine Code(s): Aeb, Atw 3 illustrations ~1033 words

Cooling system components

Note. The cooling system is under pressure when engine is warm. If necessary reduce pressure before repair. All hose connections are secured with spring clips. If replacing, only use spring clips. Pliers for spring-type clamps VAS 5024A 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 leak test of cooling system using cooling system tester V.A.G 1274 , adapter V.A.G 1274/8 and adapter V.A.G 1274/9.

Cooling system components (on body), assembly overview --> Cooling system components (on body), assembly overview .

Cooling system components (on engine), assembly overview --> Cooling system components (on engine), assembly overview .

Coolant pump and bracket, assembly overview --> Coolant pump and bracket, assembly overview

Tightening sequence, bracket to cylinder block

Coolant pump, assembly overview --> Coolant pump, assembly overview

Connection diagram for coolant hoses --> Connection diagram for coolant hoses .

Coolant, draining and refilling --> Coolant, draining and refilling .

Coolant mixture specifications --> Coolant, draining and refilling

Radiator, removing and installing --> Radiator, removing and installing

Viscous fan clutch, removing and installing --> Viscous fan clutch, removing and installing

Bushing for viscous fan clutch, removing and installing --> Bushing for viscous fan clutch, removing and installing

V-belt for coolant pump, removing and installing --> V-belt for coolant pump, removing and installing

Scheme 150

Scheme 150: Cooling system components (on body), assembly overview
Scheme 150: Cooling system components (on body), assembly overview

1 - Radiator

  1. Removing and installing --> «Radiator, removing and installing»(ref-255332-S35734497372007053000000)
  2. After replacing, replace coolant completely
  3. With ATF cooler on vehicles with automatic transmission Disassembling and assembling transmission; ATF lines and ATF cooler --> «37 AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-255345-S04734256242007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT WHEEL DRIVE
  4. Clean ATF-cooler --> «37 AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(ref-255345-S04734256242007053000000) for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT WHEEL DRIVE

2 - Securing clip

3 - Securing rubber

4 - Upper coolant hose

  1. Secured to radiator with retaining clip
  2. Check for secure fitting
  3. Connection diagram for coolant hoses --> «Connection diagram for coolant hoses»(ref-255332-S15005569702007053000000)

5 - Rubber washer

6 - Coolant Fan V7

  1. Electric fan as M-equipment

7 - Fan ring

8 - Mounting bolt

9 - 10 Nm

10 - 2-pin harness connector

11 - Lower coolant hose

  1. Secured to radiator with retaining clip
  2. Check for secure fitting
  3. Connection diagram for coolant hoses --> «Connection diagram for coolant hoses»(ref-255332-S15005569702007053000000)

12 - O-ring

  1. Replace if damaged

13 - Connector

  1. Black, 3-pin
  2. For Coolant Fan Control (FC) thermal switch

14 - Coolant Fan Control (FC) Thermal Switch F18 , 35 Nm

  1. For electric fan.
  2. Switching temperatures, 1. Stage on: 92 to 97 ° C off: 84 to 91 ° C 2. stage on: 99 to 105 ° C off: 91 to 98 ° C

15 - Seal

  1. Always replace

16 - Drain plug, 10 Nm

Scheme 151

Scheme 151: Cooling system components (on engine), assembly overview
Scheme 151: Cooling system components (on engine), assembly overview

1 - 20 Nm

2 - Toothed belt guard, lower portion

3 - O-ring

  1. Always replace

4 - Coolant pump

  1. Check for ease of movement
  2. Coolant pump and bracket, removing and installing --> «Coolant pump and bracket, assembly overview»(ref-255332-S14569863152007053000000)
  3. Disassembling and assembling --> «Coolant pump, assembly overview»(ref-255332-S31564205492007053000000)

5 - Oil cooler

6 - Retaining clip

  1. Check for secure fitting

7 - Connector

  1. 4 pin
  2. Wire socket 1 and wire socket 3 for Engine Coolant Temperature (ECT) Sensor G62

8 - Engine Coolant Temperature (ECT) Sensor G62

  1. With Engine Coolant Temperature (ECT) Gauge Sensor G2
  2. For Engine Control Module (ECM)
  3. If necessary, release pressure in cooling system before removing

9 - Sealing plugs

10 - To heater core

  1. Connection diagram for coolant hoses --> «Connection diagram for coolant hoses»(ref-255332-S15005569702007053000000)

11 - Connection

12 - 10 Nm

13 - Upper coolant pipe

  1. Secured at intake manifold
  2. Connection diagram for coolant hoses --> «Connection diagram for coolant hoses»(ref-255332-S15005569702007053000000)

14 - Throttle valve control module

  1. Heated by coolant only for engine code: ATW

15 - From heater core

  1. Connection diagram for coolant hoses --> «Connection diagram for coolant hoses»(ref-255332-S15005569702007053000000)

16 - Lower coolant pipe

  1. Secured at oil filter bracket
  2. Connection diagram for coolant hoses --> «Connection diagram for coolant hoses»(ref-255332-S15005569702007053000000)

17 - 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

18 - O-ring

  1. Replace if damaged

19 - Expansion tank

  1. Perform leak test of cooling system cooling system tester V.A.G 1274 and adapter V.A.G 1274/8

20 - Lower coolant hose

  1. From bottom of radiator
  2. Connection diagram for coolant hoses --> «Connection diagram for coolant hoses»(ref-255332-S15005569702007053000000)
  3. Secured to radiator with retaining clip
  4. Check for secure fitting

21 - Bracket

  1. For tensioner, viscous-fan clutch, generator and power steering vane pump
  2. Removing and installing --> «Coolant pump and bracket, assembly overview»(ref-255332-S14569863152007053000000)

22 - V-belt

  1. Removing and installing --> «V-belt for coolant pump, removing and installing»(ref-255332-S10991059192007053000000)
  2. Coolant pump and bracket, removing and installing --> «Coolant pump and bracket, assembly overview»(ref-255332-S14569863152007053000000)

23 - Blower wheel

Scheme 152

Scheme 152: Coolant pump and bracket, assembly overview
Scheme 152: Coolant pump and bracket, assembly overview

1 - 20 Nm

2 - Toothed belt guard, lower portion

3 - 25 Nm

4 - Ribbed belt tensioner

  1. Ribbed belt, removing and installing --> «Ribbed belt, removing and installing.»(ref-255332-S35535084012007053000000)

5 - O-ring

  1. Always replace

6 - Coolant pump

  1. Check for ease of movement
  2. Disassembling and assembling --> «Coolant pump, assembly overview»(ref-255332-S31564205492007053000000)
  3. Threaded together with bracket at cylinder block

7 - Bracket

  1. For tensioner, viscous-fan clutch, generator and power steering vane pump

8 - Grommet

9 - Brace

  1. Between bracket and cylinder block

10 - 30 Nm

11 - 25 Nm

12 - 30 Nm

  1. Observe tightening sequence

13 - 45 Nm

  1. For viscous fan clutch

14 - Brace

  1. Between intake manifold and bracket
  2. Not for USA/Canada

15 - Brace

  1. Between intake manifold and bracket

16 - V-belt

  1. Removing and installing --> «V-belt for coolant pump, removing and installing»(ref-255332-S10991059192007053000000)

17 - Bearing bushing

  1. For viscous fan clutch
  2. Removing and installing --> «Bushing for viscous fan clutch, removing and installing»(ref-255332-S42212188212007053000000)

18 - Snap ring

19 - Lower toothed belt cover: 10 Nm, belt pulley at viscous fan clutch: 30 Nm

20 - Belt pulley

  1. For viscous fan clutch
  2. Removing and installing --> «Viscous fan clutch, removing and installing»(ref-255332-S26035096282007053000000) , viscous fan clutch, removing and installing

21 - Viscous fan clutch

  1. Removing and installing --> «Viscous fan clutch, removing and installing»(ref-255332-S26035096282007053000000)