Volkswagen Workshop Service and Repair Manuals

• ◆ Perform cooling system leak testing with V.A.G 1274 and 1274/1A.
• ◆ Draining and refilling with coolant .
• ◆ Coolant mixture ratios .

Notes:

• ◆ Coolant hoses are secured either with spring clips with or screw-type clips. The spring clips can be replaced by screw clips when repairs are performed.
• ◆ For the installation of the spring clips conventional pliers such as Hazet- 798-5 are recommended.

• ◆ Renews seals and washers.
• ◆ When the radiator/heat exchanger is renewed, the coolant must be renewed.

• Radiator
• ◆ Removal:
• ‒ Remove air ducts
• ‒ Detach brackets and coolant hoses
• ‒ Remove radiator complete with fan and fan cowling
• 10 Nm
• Bracket
• Upper coolant hose

• Spring-type hose clip
• Lower coolant base
• Air duct
• Rubber washer
• Seal
• Thermo-switch for electric fan, 35 Nm

• Radiator fan
• Fan cowling
• Radiator cap
• ◆ Check with V.A.G 1274 and 1274/1A
• ◆ Test pressure 1.2...1.5 bar
• Switch for coolant shortage indicator
• To coolant pipe
• Expansion tank
• Thermo-switch
• ◆ Engine Code 2H only
• ◆ For fan run-on to cool injectors
• ◆ Checking

Notes:

• ◆ Renew gaskets and seals.
• ◆ All of the components shown in the illustration can be removed and installed with the engine in.
• ◆ Fit spring-type clips with conventional pliers, e.g., Hazet - 798-5.

• 10 Nm
• Gasket
• 20 Nm
• Upper coolant hose
• Connection
• Sealing ring
• Thermo-switch/Temperature sender
• ◆ Allocation, Engine Codes DX, EG, JH, JJ, KT:

=> Repair Group 25

• ◆ Allocation, Engine Code 2H:

=> Repair Group 24

• Retaining clip
• Sealing ring or gasket
• From heat exchanger
• To heat exchanger
• Temperature control switch/Sender
• ◆ Engine Codes DX, EG 8/78▸, JJ, KT
  Temperature control switch, 7Nm
• ‒ Connections at temperature control switch => page 19-9 , fig.1
• ◆ Engine Code EG▸7/78 Temperature sender
• Connection
• ◆ Only on vehicles with expansion tank
• ◆ To expansion tank
• Coolant pipe

• Oil cooler
• ◆ 8/84 ▸Engine Codes DX, JH, KT, 2H
• ◆ ▸7/84 => page 17-8
• Thermostat
• ◆ Checking: heat thermostat in water
• ◆ Engine Code: EG ▸7/78
  Begins opening at approx.: 80 °C
  Fully open at approx.: 105 °C
• ◆ Engine Code: EG 8/78 ▸
  Begins opening at approx.: 87 °C
  Fully open at approx.: 102 °C
• ◆ Engine Codes:
  DX, JH, JJ, KT, 2H
  Begins opening at approx.: 85 °C
  Fully open at approx.: 105 °C
• ◆ Minimum stroke = 7 mm

• Lower coolant hose
• Water pump
• ◆ Check shaft for easy movement
• ◆ Renew water pump complete in case of damage or leaks

→ Fig.1     Connections on temperature control switch

•      1 -     Wire yellow/red:
• Engine overheating - red warning lamp comes on above approx. 120 °C.
•      2 -     Wire blue/yellow:
• Engine cold - up to approx. 60 °C yellow warning lamp is on.