1996-1999 Volkswagen Golf Jetta Repair Manual

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 19 Engine-Cooling system (Page GR-19)

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 page 19 - 9 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

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 page 19 - 9 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

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 page 19 - 9 19 - Lower coolant pipe To radiator Secured at oil filter bracket Coolant hose connection diagram 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

1996-1999 Volkswagen Golf Jetta Repair Manual

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