Volkswagen 4-cyl. injection engine (1.8 and 2.0 l engine, chain drive). Manual (Edition 08.2018) - page 9

Screwed version

– Install coolant temperature sender - G62-

– Unscrew bolts -1 to 5-.
– Detach coolant pump from centring pin and pull off engine oil

cooler.

Installing

Note

♦

Renew seals and O-rings.

♦

Position the coolant pump without coolant temperature send‐

er. The coolant temperature sender projects slightly from the

coolant pump and makes it more difficult to position the coolant

pump.

– Moisten O-rings -4- with coolant.
– Check whether the two centring pins are fitted in the cylinder

block; install if necessary.

– Fit connecting piece -2- into engine oil cooler -1-.
– First, push coolant pump -3- onto connecting piece and then

fit it onto centring pin in cylinder block.

– Using a mirror, check that coolant pump is correctly »seated«

on centring pins.

Rep. gr.19 - Cooling

– Tighten bolts in the sequence -1 to 5-.

Note

Remove protective cap -arrow- if fitting a new coolant pump.

Screwed version

Further assembly is performed in the reverse order of removal.

2.3

Removing and installing toothed belt for

coolant pump

Special tools and workshop equipment required
♦ Insert tool - T10360-

♦ Torque wrench - V.A.G 1410-

Removing
– Remove small coolant pipe

⇒ page 265

– Move coolant hose -2- and wiring harness -1- clear.
– Remove bolt -arrow- and remove bracket.

253

– Remove bolt -2- at bracket for coolant pump for continued cir‐

culation - V51- . Hoses -arrows- remain connected.

– Disconnect coolant hoses -1 and 2- and move clear to one

side.

– Pull off intake manifold flap valve - N316- -2- (2.0 l engine) or

unscrew (1.8 l engine) and place to one side.

– Release wiring harness, raise and secure with cable ties.

– Unscrew bolts -arrows- and remove toothed belt guard.

Caution

The drive sprocket bolt has a left-hand thread.

Rep. gr.19 - Cooling

– Use torque wrench - V.A.G 1410- and insert tool - T10360- to

loosen bolt -1- on coolant pump drive sprocket clockwise. To

do this, counterhold at crankshaft vibration damper from

above, using hexagon socket insert AF 24.

– Unscrew bolt. Detach drive sprocket -1- and toothed belt -2-.
Installing
Install in reverse order of removal, observing the following.
– Renew drive sprocket bolt.
– Renew gaskets, seals and O-rings.
Installation position of drive gear: Collar on drive gear faces gear‐

box.
Specified torques

⇒ page 249

2.4

Renewing oil seal for coolant pump drive

Special tools and workshop equipment required
♦ Press tool -T10353-

Procedure
Proceed as follows:
– Remove toothed belt for coolant pump

⇒ page 253

– Press screwdriver -1- firmly onto section -2- of oil seal

-arrow B-.

– Lever out oil seal -arrow A-.
– Clean contact surface and sealing surface.

255

– Lubricate sealing surface of balance shaft -2- with gear oil.
– Fit oil seal -1- onto balance shaft.
• The marking “Luftseite” (or “Outside”) -arrow- should be legi‐

ble from the outside.

– Apply thrust piece -T10353- to oil seal -1- and press into cyl‐

inder block to stop using bolt -2-, taking care not to cant oil

seal.

– Fit toothed belt for coolant pump

⇒ page 253

Further assembly is performed in the reverse order of removal.

2.5

Removing and installing thermostat

Note

For vehicles with map-controlled engine cooling system thermo‐

stat, the coolant pump must be removed in order to remove the

map-controlled engine cooling system thermostat - F265- (cool‐

ant thermostat)

⇒ page 251

Special tools and workshop equipment required
♦ Bit - T10058-

Removing
Proceed as follows:
– Drain coolant

Rep. gr.19 - Cooling

– Remove bolt -2- at bracket for coolant pump for continued cir‐

culation - V51- .

Note

The continued circulation coolant pump - V51- remains installed.

– Disconnect coolant hoses -1 and 2- and move clear to one

side.

– Loosen nut -2-, remove bolt -1- and swivel support for intake

manifold slightly to right.

– Remove coarse oil separator

⇒ page 213

– Unscrew bolts -arrows- and remove connection. Allen key,

long reach 5 mm - T10058- is helpful for right-hand bolt.

– Detach thermostat.
Installing
• Specified torques

⇒ page 249

Install in reverse order of removal, observing the following.

Note

Renew gaskets, seals and O-rings.

– Clean sealing surface for O-ring.
– Moisten O-ring with coolant.

Rep. gr.19 - Cooling

– Insert thermostat -4- in coolant pump housing -5- and swivel

forwards slightly -arrow-.

– Fit connection -3- carefully (insert centralising pin -2- in guide

-1-).

Note

Depending on version, a thermostat without centring pin may be

installed.

2.6

Removing and installing coolant temper‐

ature sender - G62-

Removing
Proceed as follows:
• Engine cold.
– Pull cover off air duct (release clips on sides) -arrows-.

– Release clips -arrows- air duct at the bottom and remove duct.
– Detach air duct at bottom together with air hose.
Vehicles with sound generator:
– Remove charge air duct to sound generator

⇒ page 455

259

All:
– Release hose clip -2-.
– Unscrew bolt -4-.
– Separate electrical connector -arrow-.
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation .

– Remove air hose -items 1 and 2- and seal charge air cooler

with a clean cloth.

– Remove bolt -1- and take out air pipe downwards.

– Separate electrical connector -1- on throttle valve module -

J338- .

– Remove bolts -arrows- and detach throttle valve module -

J338- .

Rep. gr.19 - Cooling

– Remove support for intake manifold (remove nut -2- and bolt

-1-).

Coolant temperature sender - G62- with retaining clip:
– Disconnect electrical connector -1- at coolant temperature

sender - G62- .

– Detach retaining clip (press release tabs -arrows-).
– Pull out coolant temperature sender - G62- .

Note

Insert new coolant temperature sender - G62- , with O-ring, im‐

mediately into union to avoid loss of coolant.

Coolant temperature sender - G62- with retaining plate:
– Disconnect electrical connector -2- at coolant temperature

sender - G62- .

– Unscrew bolts -arrows- and remove retaining plate -1-.
– Pull out coolant temperature sender - G62- .

Note

Insert new coolant temperature sender - G62- , with O-ring, im‐

mediately into union to avoid loss of coolant.

Installing:
Install in reverse order of removal, observing the following.
♦ Renew O-ring.
♦ After completing repair: check coolant level.

2.7

Assembly overview - coolant pipes

261

1 - Coolant pipes (front)

❑ Removing and installing

⇒ page 262

2 - Coolant hose

❑ From turbocharger

3 - Coolant hose

❑ To coolant expansion

tank

4 - Bolt

❑ 3.5 Nm

5 - O-ring

❑ Renew

6 - Coolant hose

❑ To heat exchanger for

heater unit.

7 - Small coolant pipe

❑ Removing and installing

⇒ page 265

8 - Bolts

❑ 9 Nm

9 - Coolant hose
10 - Bolt

❑ 5 Nm

11 - Coolant hose

❑ From continued coolant

circulation pump - V51- .

12 - Coolant hose

❑ To continued coolant

circulation pump - V51- .

2.8

Removing and installing front coolant

pipes

Special tools and workshop equipment required
♦ Spring-type clip pliers - VAS 6362-

Rep. gr.19 - Cooling

♦ Drip tray for workshop hoist - VAS 6208-

Removing
Proceed as follows:

WARNING

The cooling system is under pressure when the engine is hot!
Danger of scalding by steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐

fully to release pressure.

– Open filler cap on expansion tank.
– Pull cover off air duct (release clips on sides) -arrows-.

– Release clips -arrows- air duct at the bottom and remove duct.
– Detach air duct at bottom together with air hose.

263

Vehicles with sound generator:
– Open latch -1-, unclip fuel lines -2- and slacken bolts -3-. Re‐

move charge air pipe.

Vehicles with activated charcoal filter in engine compartment:

– Pull off breather line -1-, release activated charcoal filter -A-

and remove upwards -B-. Place activated charcoal filter to one

side.

All:
– Release hose clip -2-.
– Unscrew bolt -4-.
– Disconnect electrical connector -arrow- and move electrical

wires clear.

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation .

– Remove air hose -items 1 and 2- and seal charge air cooler

with a clean cloth.

Rep. gr.19 - Cooling

– Remove bolt -1- and take out air pipe downwards.

– Place drip tray - VAS 6208- beneath engine.
– Disconnect coolant hoses from continued coolant circulation

pump - V51- -arrows-.

– Unscrew bolts -1 and 2- and disconnect coolant pipes (front)

from coolant hoses -arrows-.

Installing
• Specified torques

Installation is carried out in the reverse order. When installing,

note the following:

Note

♦

Renew gaskets and seals.

♦

Secure all hose connections with the correct type of hose clips

(same as original equipment) ⇒ EKTA (Electronic parts cata‐

logue) .

– Installing hose connections with plug-in connectors

⇒ page 431

2.9

Removing and installing small coolant

pipe

Special tools and workshop equipment required

265

♦ Spring-type clip pliers - VAS 6362-

Removing
Proceed as follows:
– Drain coolant

– Remove air filter

⇒ page 467

Vehicles with sound generator:
– Remove charge air duct to sound generator

⇒ page 455

All:
– Release hose clip -2-.
– Unscrew bolt -4-.
– Separate electrical connector -arrow-.
– Remove bolt -1- and take out air pipe downwards.

– Remove bolts -arrows- and detach electrical connectors

-1 to 3- from retainer.

Rep. gr.19 - Cooling

– Place electrical wiring at small coolant pipe to one side

-arrow-.

– Unscrew bolts -2 and 3-.
– Detach small coolant pipe from coolant pump and coolant ho‐

ses -1 and 4-.

Installing
• Specified torques

Installation is carried out in the reverse order. When installing,

note the following:

Note

Secure all hose connections with the correct type of hose clips

(same as original equipment) ⇒ EKTA (Electronic parts cata‐

logue) .

– Installing hose connections with plug-in connectors

⇒ page 431

2.10

Continued coolant circulation pump - V51- - exploded view

1 - Bracket
2 - Bolt

❑ 40 Nm

3 - Coolant hose
4 - Coolant hose
5 - Continued coolant circula‐

tion pump - V51-
6 - Bracket
7 - Bolt

❑ 8 Nm

267

2.11

Removing and installing continued cool‐

ant circulation pump - V51-

Special tools and workshop equipment required
♦ Hose clamps to 25 mm - 3094-

♦ Spring-type clip pliers - VAS 6362-

Removing
Proceed as follows:

WARNING

The cooling system is under pressure when the engine is hot!
Danger of scalding by steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐

fully to release pressure.

– Open filler cap on expansion tank.
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation .

Rep. gr.19 - Cooling

– Disconnect electrical connector -1- for continued circulation

coolant pump - V51- .

– Place drip tray - VAS 6208- beneath engine.
– Clamp off coolant hoses -arrows- with hose clamps - 3094- .
– Disconnect coolant hoses from continued coolant circulation

pump - V51- .

– Remove bolt -2- and detach continued coolant circulation

pump - V51- .

Installing
• Specified torques

⇒ page 267

Install in reverse order of removal, observing the following.
– Check coolant level.

269

Radiator and radiator fans

Assembly overview - radiator, fan cowl and radiator fan (Passat,

CC, Golf, Eos, Scirocco)

⇒ “3.2 Installing radiator identification sensor G611 , engine code

CBFA”, page 271

Assembly overview - radiator, radiator cowl and radiator fan (Ti‐

guan)

⇒ page 272

Removing and installing radiator cowl

Removing and installing radiator fan - V7- and radiator fan 2 -

V177-

Removing and installing radiator (Passat, CC, Golf, Eos, Sciroc‐

co)

Removing and installing radiator (Tiguan)

3.1

Assembly overview - radiator, fan cowl and radiator fan (Passat, CC, Golf,

Eos, Scirocco)

1 - Radiator fan - V7-

❑ Removing and installing

2 - Nut

❑ 10 Nm

3 - Radiator cowl
4 - Lower coolant hose

❑ To connection for ther‐

mostat.

5 - Retaining clip
6 - Radiator outlet coolant tem‐

perature sender - G83-
7 - O-ring

❑ Renew if damaged

8 - Upper coolant hose

❑ From coolant pump

9 - O-ring

❑ Renew if damaged

10 - Bolt

❑ 5 Nm
❑ To charge air cooler

11 - Radiator/cooler

❑ Removing and installing

❑ Engine code CBFA: with

radiator identification

sensor - G611-

⇒ page 271

12 - Nut

❑ 10 Nm

Rep. gr.19 - Cooling

13 - Bolt

❑ 5 Nm
❑ To radiator

14 - Radiator fan 2 - V177-

❑ Removing and installing

3.2

Installing radiator identification sensor -

G611- , engine code CBFA

Note

♦

Radiator identification sensor - G611- can only be renewed

together with the radiator.

♦

The installation position of the radiator identification sensor -

G611- depends on its version.

Installing:
– Apply 2 grammes of adhesive - AMV 195 KD1 01- to cylindrical

part of the new sensor -arrow-.

– Press new sender into retainer on radiator until it engages.

Installed at bottom:

-Arrow- points in direction of travel
-A- Radiator
-B- Radiator identification sensor - G611-

Installed at top:

-Arrow- points in direction of travel
-1- radiator
-2- Radiator identification sensor - G611-

271

3.3

Assembly overview - radiator, radiator cowl and radiator fan (Tiguan)

1 - Radiator/cooler

❑ Removing and installing

2 - O-ring

❑ Renew if damaged

3 - Union

❑ To remove, pull out re‐

taining clip.

4 - Spring-type clip

❑ Remove and install with

hose clip pliers - VAS

6340- .

5 - Coolant hose

❑ Connection diagram for

coolant hoses

6 - Upper coolant hose

❑ To connection on cylin‐

der head.

❑ Connection diagram for

coolant hoses

7 - Expansion tank

❑ Check cooling system

for leaks using cooling

system tester - V.A.G

1274 B- and adapter for

cooling system tester -

V.A.G 1274/8-

8 - Connector
9 - Cap

❑ Check using cooling

system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-

❑ Pressure relief valve must open at pressure of 1.4 to 1.6 bar

10 - 5 Nm
11 - Plastic inserts

❑ For securing bolts.

12 - Bracket
13 - Cowling
14 - 5 Nm
15 - Radiator fan 2 - V177-

❑ Removing and installing

16 - Connector
17 - Radiator fan - V7-

❑ With radiator fan control unit - J293-

18 - Bracket

❑ For connector.

Rep. gr.19 - Cooling

19 - Retaining clip
20 - Lower coolant hose

❑ To connection for thermostat.
❑ Connection diagram for coolant hoses

21 - Radiator outlet coolant temperature sender - G83-
22 - Lower coolant hose

❑ To connection for thermostat.
❑ Connection diagram for coolant hoses

23 - Union

❑ To remove, pull out retaining clip.

24 - 10 Nm

3.4

Removing and installing radiator cowl

Removing
– Pull cover off air duct (release clips on sides) -arrows-.

– Release clips -arrows- air duct at the bottom and remove duct.

– Unscrew bolts -1- from above.

Note

The left bolt is located below the coolant union.

– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Noise insulation .

273

Tiguan
– Remove bracket -1- by unscrewing securing bolts -arrows-.

All
– Disconnect electrical connector -2-.
– Remove bolts -3- and take out air cowl downwards.

– Cover radiator using protective mat - VAS 531 003- .
Installing
Install in reverse order of removal, observing the following.
♦ Install radiator cowl from below.
♦ Specified torques

3.5

Removing and installing radiator fan -

V7- and radiator fan 2 - V177-

Removing
Proceed as follows:
– Remove radiator cowl

– Disconnect electrical connector -1-.
– Move electrical wiring clear.
– Unscrew nuts -arrows- and remove radiator fans.
Installing
Install in reverse order of removal.
• Specified torques

Rep. gr.19 - Cooling

3.6

Removing and installing radiator (Pas‐

sat, CC, Golf, Eos, Scirocco)

Removing
Proceed as follows:
– Drain coolant

– Remove radiator cowl

– Detach top coolant hose from radiator -arrow-.

– Unscrew air duct from lock carrier -arrows- and remove air

duct.

– Engine code CBFA: Disconnect connector for radiator identi‐

fication sensor .

– Unscrew bolts -1 and 2- and remove radiator upwards.
Installing
Install in reverse order of removal.
• Specified torques

3.7

Removing and installing radiator (Ti‐

guan)

Removing
Proceed as follows:
– Drain coolant

– Remove radiator cowl