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Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl.

5V Turbo Engine Mechanical, Engine Code(s): AWD


19 Engine-Cooling system (Page GR-19) Cooling system components, removing and installing Coolant hose connection diagram Coolant pump, removing and installing Coolant, draining and refilling Cooling system components (on body) Cooling system components (on engine) Radiator, removing and installing Thermostat, removing and installing

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-1)

Notes: The cooling system is under pressure when engine is warm. If necessary reduce pressure before beginning repairs. All hose connections are secured with spring clips. If replacing, only use spring clips. VAS5024 assembly tool or VAG1921 pliers are recommended for installing spring clips. When installing coolant hoses, make sure they are free of stress and do not come into contact with other components (observer markings on coolant connections and hoses). Use VAG1274 cooling system tester with VAG1274/8 and VAG1274/9 adapters to test coolant system for proper seal Cooling system components (on body) page 19-2. Cooling system components (on engine) page 19-5. Coolant hose connection diagram page 19-9. Draining and refilling coolant page 19-10. Coolant mixture specifications page 19-10 ; Coolant, draining and refilling.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-2)

Cooling system components (on body)

1 - Radiator Removing and installing page 19-15 After replacing, completely replace coolant 2 - O-ring Replace if damaged 3 - Upper coolant hose Secured to radiator with retaining clip Check for secure fitting Coolant hose connection diagram page 19-9 4 - Intake air elbow 5 - 10 Nm 6 - Auxiliary fan For vehicles with M-equipment

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-3)

7 - Fan ring 8 - Retaining clip Check for secure fitting 9 - Connector 10 - Radiator fan 11 - Bracket For fan connector 12 - Lower coolant hose Secured to radiator with retaining clip Coolant hose connection diagram page 19-9 13 - O-ring Always replace

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-4)

14 - Coolant Fan Control (FC) thermal switch - F18 - , 35 Nm For electric fan. Switching temperatures, 1. Stage 2: On: 92 to 97 C Off: 84 to 91 C 2. Stage 2: On: 99 to 105 C Off: 91 to 98 C 15 - Bracket For radiator Note installed position 16 - 15 Nm

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-5)

Cooling system components (on engine)

1 - 15 Nm 2 - Toothed belt Mark direction of travel before removing Check for wear Do not bend 3 - Coolant pump Check for ease of movement Completely replace if damaged or leaking Removing and installing page 19-18 4 - O-ring Always replace 5 - Coolant thermostat Checking: warm thermostat in hot water Starts opening at approx. 87 C Ends at approx. 102 C Opens at least 7 mm

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-6)

6 - O-ring Replace if damaged 7 - Connection sleeve 8 - To heater core Coolant hose connection diagram 9 - O-ring Replace if damaged 10 - Connector 4 pin 11 - Engine Coolant Temperature (ECT) sensor - G62 With sensor for Engine Coolant Temperature (ECT) gauge (G2) For Engine Control Module (ECM) If necessary, release pressure in cooling system before removing Checking: Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo OBD II Fuel Injection & Ignition , Repair Group 01; Engine Control Module (ECM) DTC memory, checking and erasing

page 19-9

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-7)

12 - Retaining clip Check for secure fitting 13 - Upper coolant line To top of radiator Secured at intake manifold Coolant hose connection diagram 14 - 10 Nm 15 - O-ring Replace if damaged 16 - Lower coolant hose From bottom of radiator Coolant hose connection diagram page 19-9 Secured to radiator with retaining clip Check for secure fitting 17 - Oil cooler Removing and installing page 17-8 item no. 22

page 19-9

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-8)

18 - From heater core Coolant hose connection diagram 19 - Lower coolant pipe To radiator Secured at oil filter bracket Coolant hose connection diagram

page 19-9

page 19-9

20 - Cap Check using VAG1274 cooling system tester with VAG1274/9 adapter Test pressure: 1.4 to 1.6 bar 21 - Expansion tank Perform cooling system leakage test using VAG1274 cooling system tester with VAG1274/8 adapter 22 - To turbocharger Coolant hose connection diagram page 19-9

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-9)

Coolant hose connection diagram

1 - Radiator 2 - Oil cooler 3 - Coolant thermostat housing 4 - Cylinder head/Cylinder block 5 - Expansion tank 6 - Turbocharger 7 - Heater core 8 - Connection sleeve 9 - Transmission oil cooler Only for automatic transmission 10 - Lower coolant pipe 11 - Intake manifold 12 - Drain screw

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-10)

Coolant, draining and refilling

Special tools and equipment T10007 Refractometer VAG1306 drip tray VAS5024 assembly tool for spring-type clamps

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-11)

Draining WARNING! Hot steam may escape when expansion tank is opened. Cover cap with a cloth and open carefully. - Open cap for coolant expansion tank. - Remove noise insulation pan: Repair Manual, Body-Exterior , Repair Group 50; Front chassis; Noise insulation (gas engine) - assembly overview

- Remove drain screw (arrow) to drain coolant from radiator.

- Also remove coolant hose at oil cooler (arrow) to drain coolant from engine. Notes: Observe disposal regulations.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-12)

Filling Notes: Only use coolant additive G12 (according to TL VW 774 D). Characteristic: red color Do not mix G12 with any other type of coolant or additive! If the fluid in expansion tank is brown, G12 has been mixed with another coolant. In this is the case, coolant must be replaced. "G12" and coolant additives marked "In accordance with TL VW 774 D" prevent frost and corrosion damage, scaling and also raise the boiling point of the coolant. Therefore, cooling system must be filled year round with frost and corrosion protection additives. A higher boiling point improves engine reliability under heavy load particularly in countries with tropical climates. Frost protection additives protect against frost to about - 25 C (about - 35 C in arctic climates). 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%.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-13)

If for climatic reasons greater frost protection is required, the amount of G 12 can be increased, but only up to 60% (frost protection to about - 40 C), otherwise frost protection and cooling effectiveness will be reduced.

The T10007 refractometer is recommended for determining frost protection density. If the radiator, heater core, cylinder head or cylinder head gasket is replaced, completely replace the engine coolant. Recommended mixture ratios:

1)

The quantity of coolant can vary depending upon vehicle options.

- Install drain screw in radiator.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-14)

- Slide coolant hose onto oil cooler connection sleeve and secure using spring-type clamps.

- Fill coolant up to the max. marking at expansion tank. - Close expansion tank. - Start engine and maintain an engine speed of about 2000 RPM for approx. 3 minutes. - Let engine run until fan starts up. - Check coolant level and top off if necessary. With engine warm, coolant level must be at max. marking, with engine cold, it must be between min. and max. marking.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-15)

Radiator, removing and installing

Special tools and equipment T10007 Refractometer VAG1306 drip tray VAG1331 torque wrench (5 to 50 Nm) VAS5024 assembly tool for spring-type clamps

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-16)

Removing - Drain coolant page 19-10. - Remove front bumper: Repair Manual, Body-Exterior , Repair Group 63 - Remove coolant hoses from radiator. - Disconnect harness connector from thermal switch. - Bring the lock carrier into service position: Repair Manual, Body-Exterior , Repair Group 50, Front chassis; Lock carrier service position - Remove mounting bolts of radiator and remove radiator downward with fan. Notes: Vehicles with air conditioning - See additional notes and assembly steps

page 19-17.

Installing Installation is reverse of removal, noting the following: - Fill up coolant page 19-10.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-17)

Additional notes and assembly steps for vehicles with A/C system

CAUTION!
A/C coolant circuit must not be opened. Notes: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may become damaged. - Unscrew retaining clamp(s) for coolant lines. - Unscrew condenser from radiator and secure at lock carrier.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-18)

Coolant pump, removing and installing

Special tools and equipment T10007 Refractometer VAG1306 drip tray VAG1331 torque wrench (5 to 50 Nm) VAS5024 assembly tool for spring-type clamps

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-19)

Notes: Always replace seals and gaskets. Lower portion of toothed belt guard can remain installed. Toothed belt stays attached to crankshaft toothed belt gear. Cover the toothed belt with a cloth to protect it from coolant before removing the coolant pump. Removing - Drain coolant page 19-10. - Remove ribbed belt page 13-8. - Remove upper and middle toothed belt guards page 13-11 , ribbed belt, removing, installing and tensioning. - Remove toothed belt from toothed belt gear of coolant pump page 13-11.

- Remove coolant pump mounting bolts -1- and remove coolant pump -2- .

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-20)

Installing Installation is reverse of removal, noting the following: - Moisten new O-ring -3- with coolant. - Insert coolant pump in cylinder block and tighten mounting bolts. Tightening torque: 15 Nm - Install toothed belt and adjust timing page 13-11 - Install ribbed belt page 13-8. - Fill up coolant page 19-10.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-21)

Thermostat, removing and installing

Special tools and equipment T10007 Refractometer VAG1306 drip tray VAG1331 torque wrench (5 to 50 Nm) VAS5024 assembly tool for spring-type clamps

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-22)

Removing Notes: Always replace seals and gaskets. - Drain coolant page 19-10.

- Disconnect coolant hose from connection sleeve -3-. - Remove mounting bolts -4- of connection sleeve -3- and remove connection sleeve 3- with coolant thermostat -1-. Installing Installation is reverse of removal, noting the following: - Moisten new O-ring -2- with coolant. - Insert coolant thermostat -1- in connection sleeve -3- and rotate 1/ turn (90 ) to the 4 right. - Insert connection sleeve -3- with coolant thermostat -1- into engine block.

Volkswagen Jetta, Golf, GTI 1999, 2000 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s): AWD
Cooling system components, removing and installing (Page 19-23)

Notes: Coolant thermostat brackets must be close to vertical.

- Tighten mounting bolts -4- . Tightening torque: 15 Nm - Fill up coolant page 19-10.