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 - RadiatorRemoving and installing page 19-15 After replacing, completely replace coolant

2 - O-ringReplace if damaged

3 - Upper coolant hoseSecured to radiator with retaining clipCheck for secure fittingCoolant hose connection diagram page 19-9

4 - Intake air elbow5 - 10 Nm6 - 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 ring8 - Retaining clip

Check for secure fitting9 - Connector10 - Radiator fan11 - Bracket

For fan connector12 - Lower coolant hose

Secured to radiator with retaining clipCoolant hose connection diagram page 19-9

13 - O-ringAlways 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 NmFor electric fan.Switching temperatures,

1. Stage 2:On: 92 to 97 COff: 84 to 91 C

2. Stage 2:On: 99 to 105 COff: 91 to 98 C

15 - BracketFor radiatorNote 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 Nm2 - Toothed belt

Mark direction of travel before removingCheck for wearDo not bend

3 - Coolant pumpCheck for ease of movementCompletely replace if damaged or leakingRemoving and installing page 19-18

4 - O-ringAlways replace

5 - Coolant thermostatChecking: warm thermostat in hot waterStarts opening at approx. 87 CEnds at approx. 102 COpens 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-ringReplace if damaged

7 - Connection sleeve8 - To heater core

Coolant hose connection diagram page 19-9 9 - O-ring

Replace if damaged10 - Connector

4 pin11 - 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 removingChecking:

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 clipCheck for secure fitting

13 - Upper coolant lineTo top of radiatorSecured at intake manifoldCoolant hose connection diagram page 19-9

14 - 10 Nm15 - O-ring

Replace if damaged16 - Lower coolant hose

From bottom of radiatorCoolant hose connection diagram page 19-9 Secured to radiator with retaining clipCheck for secure fitting

17 - Oil coolerRemoving 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 coreCoolant hose connection diagram page 19-9

19 - Lower coolant pipeTo radiatorSecured at oil filter bracketCoolant hose connection diagram page 19-9

20 - CapCheck using VAG1274 cooling system tester with VAG1274/9 adapterTest pressure: 1.4 to 1.6 bar

21 - Expansion tankPerform cooling system leakage test using VAG1274 cooling system tester with VAG1274/8 adapter

22 - To turbochargerCoolant 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 - Radiator2 - Oil cooler3 - Coolant thermostat housing4 - Cylinder head/Cylinder block5 - Expansion tank6 - Turbocharger7 - Heater core8 - Connection sleeve9 - Transmission oil cooler

Only for automatic transmission10 - Lower coolant pipe11 - Intake manifold12 - 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 equipmentT10007 RefractometerVAG1306 drip trayVAS5024 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)

DrainingWARNING!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)

FillingNotes:

Only use coolant additive G12 (according to TL VW 774 D). Characteristic: red colorDo 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 equipmentT10007 RefractometerVAG1306 drip trayVAG1331 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.InstallingInstallation 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 systemCAUTION!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 equipmentT10007 RefractometerVAG1306 drip trayVAG1331 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)

InstallingInstallation 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 equipmentT10007 RefractometerVAG1306 drip trayVAG1331 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)

RemovingNotes: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-.InstallingInstallation is reverse of removal, noting the following:- Moisten new O-ring -2- with coolant.- Insert coolant thermostat -1- in connection sleeve -3- and rotate 1/4 turn (90 ) to the

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.