Volkswagen Workshop Service and Repair Manuals

Note:

• ◆ Hose connections are secured with either spring-type clips or screw-type clips. Spring-type clips may only be installed together with the appropriate coolant hoses and connections. When performing repairs, spring-type clips can be replaced by the screw type.
• ◆ Commercially available pliers such as Hazet 798-5 are recommended for fitting clips of the spring type.
• ◆ Always renew oil seals and O-rings.

Draining and filling coolant

Coolant mixture ratios: draining and filling coolat => page 19-7

Checking cooling system and radiator cap => page 19-9

Subsequent installation of radiator with modified attachment => page 19-10

Service installation of cardboard air deflectors => page 19-12

Parts of cooling system on body end

• Air guide
• 10 Nm
• Bracket
• Radiator
• ◆ Renew entire coolant on installing a new radiator
• ◆ ä12.80 radiator attachment with bonded rubber bush => page 19-10
• ◆ Removal:
• ‒ Remove radiator grille
• ‒ Unscrew air guides
• ‒ Detach bracket and coolant hoses
• ‒ Lift out radiator complete with radiator cowling and fan.
• Upper coolant hose
• Lower coolant hose
• Radiator cowling

• Radiator fan
• To coolant pipe
• Expansion tank
• Cap
• ◆ Checking cooling system and radiator cap => page 19-9
• Thermoswitch, 35 Nm
• ◆ For electric fan
• ◆ Cut-in temperature:

• ◆ Cut -out temperature

• Washer
• ◆ Renew
• Rubber disc

Parts of cooling system on engine end

Note:

• ◆ All the parts shown can be removed and installed with the engine in situ.
• ◆ The thermostat 08.78 ▸is not to be installed in vehicles ▸ 07.78 because fan thermoswitch, temperature control switch and temperature gauge are not matched to the higher coolant temperature.

• To radiator, top
• Connection
• Screw plug, 10 Nm
• Thermoswitch for automatic choke/temperature sender, 10 Nm
• ◆ Renew
• O-ring
• ◆ Renew
• Plug
• Thermoswitch for automatic choke/temperature sender

• Retaining spring
• Temperature sender/plug
• Seal
• Gasket/O-ring
• ◆ Renew
• Temperature sender, 10 Nm
• 10 Nm
• To heat exchanger
• From heat exchanger
• To intake manifold
• To expansion tank
• Coolant pipe
• Temperature sender/screw plug, 10 Nm
• To radiator, bottom
• Connection

• Thermostat
• ◆ Checking : Heat thermostat in water bath
• ◆ ä07.78

• ◆ 08.78 ä

• ◆ Stroke: min. 7 mm

• 20 Nm
• Gasket
• ◆ Renew
• Pulley
• Coolant pump
• ◆ Check that shaft runs smoothly
• ◆ Renew complete coolant pump if damaged and leaking