19 Engine Cooling System Index Air-cooled = Cooling air control fap adjusting 19.3, + Cooling fan removing 19.3 |— Fan housing assombly 19.2 removing 19.3 |— Snap-lock wiring connectors instaling 19.19 |— Thermostat assembly 19.2 tension, adjusting 19.3 Diesel = Anttesze hydrometer ‘checking 19.7 |— Coolant assembly 19.4 draining/fiing 19.6, mixture ratio 19.5 Pipes, replacing 19.7 |— Snap-lock wiring connectors instaling 19.19 |— Pressure Cap chocking 18.7 Water-cooled — Antireeze hydrometer checking 19.17 Coolant assembly 19.8, 19.11, 19.14 raining/filing 19.15 ‘oxpansion tank, checking 19.18 hose layout 19.10 leak chacks 19.17 rmocture ratio 19.18 ‘ofl tank 19.9, 19.13, — Hose spring clamps removing/instaling 19.16 — Hot footwell kt instaling 19:20 — Radiator ‘assembly 19.12 thermo-switch 19.12 19.119 Engine-Cooling System “> Rolle 8 ‘cheek f6r free movement 20 Non (15 ft 1B) ‘Thermostat yy ‘checking Fig. § as Cooling alr contrat fap ‘adjusting Fig. 4 £20 Nn (15 1B) Cooling fan with pulley ramoving Fig. 2 20 Non (15 815) Vebett ‘adjusting Fig. + 49.2 cxiveie [ir cooled-AFC Fan housing 42 43Engine-Cooling System 19 Fig. 1 V-belt tenston, adjusting — loosen bolts 1 and 2 1ove alternator to tension belt bell deflection must be 10=15mm : (3/8-9/18 In.) in middle when pressing firmly with thumb —tighten baits Fig. 2. Cooling tan with pulley, ramoving — remove bolts (arrows) Fig. 3 Fan housing, removing = disconnect cooling air control flap cable — remove bolts (arrows) — remove housing Fig. 4 Cooling air control tlap, adjusting = press flaps to fully closed position and tighten cable clamp Note ‘Bent ends of return spring must rest on boss of housing (arrow A} and on cable guide (arrow 8) Fig. 5 Thermostat, checking — put thermostat in water 85-90 (185-194°) # a= min, 46 mm (1 13/16 in) A V-belt Cooling fan Thermos Air cooled-AFC 19.319 Engi Note ‘The cooling systems of all Vokiswagen vehicles are filed atthe factory wih a mixture of water and an, antireeze solution (G 11) with corrosion inhibitors, This coolant mixture should be used year-round. Phosphate-ree antt-reeza prevents fost and ‘corrosion damage, the formation of chalk and in ‘addition, it raises the Bolling point of water. Due to the higher bolling point the coolant is an aid to operational efciency, wien the engine is operating ‘under ful load, particulary in tropical ciates. © to healer: ‘Coolant temporature —_/ gouge eanser Nm GI. A = dra td ea. Wetar pump bet @neae in) ‘ing syetor Fg. & ie — Cooling System ‘ Ms tank TEE Tme A Senteane 4 ols max and min marks When replacing coolantiantireeze solution in all Volkswagen models, all madel years, use phasphate- ‘CAUTION nitzeeze other than speciied by Volkswagen ‘may cause corrosion of the coating system ‘thus loading to engine overheating and damage. Thways uso new gasket when insating paris, Cooling system pars can be removed ane installed with angine in vehicio, cooling syste fling Fig. 200 Fig. 4 o ior rear | 40 Nm (7 1) Trarmestat opering begins: approximately BSC (a5) uly open: approximately 105°C wry stoke: sania 7 mm (0.279, a) ‘CAUTION Coolart/antitrseze must nat be reused when replacing engina, cylinder head, cylinder head ‘gasket, radiator and heater core, ‘tee coolanvantitreeze ZVW237 102. 19.4 eects tom ssentn |_Dese! ‘coating system caining Fig. 1Engine-Cooling System 19 Coolant mixtureratio Coolant capacity 76.010 (169US at) . Outside Temperature Antifreeze Water : = 28°C (13°F) 6.41 (6.75 US ab 8.8 r(10.15 US ab) = 25°C (= 30°F) 8.0itr (645 US ab 8.0 itr@.45 US at) Brosthor valve open valve whan tiling ‘Theemoswiteh for tan stage | ee eee ere son @2 tb) dunich ON: 9 0 98° 200 ta 208 Silth OFF: 88 1 99°C (90 %0 20°F) Thermosyiteh for fon stage . s0nm22 I) BO ‘toh ON: 100-108" 2122-224 smitoh OFF: 85*~100"G o03*-212"F) Airduct Fon motor: 40Ne (71H). & 15 No (14) ~ Fen shroud RS ON (7 feb) to-eylindor head #7 CAUTION improper ive open seraea Gamps ean tear ose and cous colt oa 10 water pump ‘CAUTION Coolanvantiresze must not be reused when =z raplacing engine, cylindar head, cylinder head {gaskat, raciator and heater core, 4s Diesel Cooling system as19 Engine—Cooling System Cooling system, draining'tilling “The coding systems of eit Voskswagen vehicles are filoc at tha factory with a mixture of water and an antireeze solution (G11) with corrosion intibitors, ‘Tis coolant mixture should be used year-round, Phosphate-t0 ant/-reaze prevents frost and ‘corrosion damage, the formation of chalk and in _addtion, ries the Boling point of water. Due to the higher boling pain the coolant Is an aid to ‘operational efficiency, wien the engine is operating under ful foad, particulary in ropleal climates. CAUTION Coolanwanttreeze must not be reused when replacing engine, cylinder head, cylinder head gasket, radiator and Neater core. When replacing coolantientireeze sakion In all Volkswagen madsis, al model yoars, use phosphate- {tee coolantanbireaze ZVW/237 102. ‘CAUTION Part numbers are for reference only. Always, cock win your Pats Doparent fr latest Fig. 4 Cooling system, draining —tully open heater controls ‘open cap on expansion tank ~disconnect lower coolant hose 4 from water pump at connection pipe disconnect center cooiant hose 2 trom water pumo Note * ave Coolant for rouse (see caution) ‘When removing radiator, drain rest of coolant by detaching lower hose from ragiator V9.G cosins sm cranngtting Fig. 2 Cooling system, filing Fig. 3 Set heater controis to position WARM ‘open breather valve (arrow) on radiator Cooling system, iting ll cooling system via expanaion tank (arrow) until tank s filled 0 beim and remains filled —tun engine at about 2600 rpm unt coolant flows at breather vaive with NO oubbl —close breather valve check coolant level and top up as necessary —close expansion tank with capEngine-Cooling System 19 8 Pr Fig. 4 Cooling system, filing Fig. Pressure cap, chacking ~attach cap on tester A HM ROSNER ee oma frron + A= Stan testar ST.255A, AC-PCT-S a oF equivalent apply a pressure of 0.910 1.15 bar (1110 18 ps) + if pressure reilef valve opens within this range, cap is OK Antifreeze hydrometer, checking Caliration of hydrometer must be checked frequently to ensure accuracy. — mix a 50/80 mixture of antifreeze and water together in a small container —hydrometer should read ~95°C (—30°F) ‘itt, put a mark (paint dot to indicate where =35°C (90°F) should be. Fig. Cooling system, checking ~ attach tester A in place of prossure cep A= Slant tester ST.255A, ACPCTS orequivafent ~ apply pressure of approximately 1 bar itpsh 1 it pressure romaine constent, system is ok ‘Antifreeze hydrometer, checking eset | seme 19.719 Engine—Cooating System Coolant pipes, replacin remove flank ae e . — remove steel coolant pipes ‘Since March 1985 the steel coolant pipes have been — pull back hoses for heater to engine from cross replaced with plastic coolant pipes. eee In cages of repair, the original steel coolant pipes must be replaced with the new plastic pipes, ‘Singe the diameter of the plastic coolant pipes is larger than the steel pipes, the hose hole apenings in the engine compartment and cross members must be enlarged Also, connecting hoses to engine and radiator must be replaced. Parts required CAUTION v 3.6 in} Part aumbers are for reerence only. Always check with your Parts Deparment for latest Eemeten — rework holes for heater to engine in cross member (as shown) — rework holes in cross member and engine een Eat neenen Loren) ‘compartment wall fo side and downward Piasic pie (rom | 251 121 27a | 1 — cover sheet metal edges on cross member with cylinder head) trim bead Plastic pipe 2st 121 soaa | (o coolant pump) Engine hose (rom | 068 121 vin | 1 cinder head) Engine hose ose 121 ora | (to coolant pur) Radiaior nose (rom] 251 121 82 | 1 eyfinder head) Radiator hose | 251 121 0804 | 1 ( coolant pum) Clamps 414 261 679 Worm dive hose | obtain folly | 2 clamps Tiewrape obtain only | __X “Tim beading obiain localy | _* — push plastic pipes ftom engine side through cross member and fasten to attachment tabs on cross ‘member and engine wall with a worm drive hose clamp (as shown) 19.7€ coctntreres ening [Dise! “bend and attach clamps Part No. 417 261 679 to shape and secure plastic pipes to cross member In front (arrow) — attach clamp in back with self tapping screws (arrow) = te coolant water pipes and heater hoses together with te wraps (see illustration 19-437 at 30 om (@pproximately 12 in.) intervals, Engine — Cooling System 19 Installing new coolant water hoses - to engine/radiator Note Vehicles up to 8/82 ~ shorten hose Part No. 251 121 083H for return flow from the radiator to coolant pump to fit “note the diferent hose diameters of 32 mm (1-114 in.) and 88 mm (1-31/64 in.) Vehicles from VIN 24¢ 017 500 (approximately 12/82) — connecting sleave diameter for hose Part No, 068 321 f01H on expansion tank was increased from 20 mm {25/92 in.) to 32 mm (1-144 in) \ Proceed as folios when ingf Part No, 068 121 101H to yehicies with 20 mm (25/82 in.) connecting s — cut off original coptént hose (with 20 mm sleeve) approximately 120 mm (4-11/16 in.) trom expansion tank — install new coolant water hose, and shorten ‘connecting sleeve to expansion tank to match length of original part ‘— connect bot? ends of hose with aid of piece of pipe (made locally) of 20 mm (25/82 in.) diameter — secure with clamps a Diesel cost one pasts 19.71 9 Engine—Cooling System trang Po Fo. 4 vow “Ig | 10 % ‘Aways ropace at gaskets. Al parts of 2ooHng fertaes Fay. 8 fyniem can be removed and insalee Wah engine ietaled, i ela expert ak ap Coolant level warning a ti ight whch Spring comp removinginsatieg Fig. enn 20 Nm (15 Rb) oe Bae. irene 20 Kim (15 nm) Xe 20 Nom (15 ft 18) To (61 tnt) a choc 5 ormgetat in wotee ‘pening begins" approximately 85°C (185°) ‘pening ends. = approximately 105°C (221°) stoke sitar 8 ny (0.335 in) 19.8 conn Le | LeEngine-Cooling System 19 ‘CAUTION Coolanvantitveeze must not be reused when replacing engine, cylinder head, cyinger head ket, raciaor anc heater core 10 radiator: Blaedor connection valve ‘pen when filling oF bleeding cooling system 300 Fig. 6 ~e 7 Nin (81 Jn. 1 v Rell tank te min. and max. marks ff tihng system Fig, $10 Fig. 8 20.Nm (15 18) ‘ 0 coolant expansion - tank Se , = 20.mm (35 #18) } i 1983-1985 Water-cooled | 6 siag system 19.919 Engine—Cooling System / Bleeder screw / Radiator ‘Teansmission cooter (ATF) (Automatic Transmission) t i 1 i 1 (on water-cooled engines 1989-1865 my. a coolant Jean the rear heat exchanger area may be duo 10 0c nose fat the metal T-plocs wich Connects the ‘eed hose to the main coolant hose. An improved, CS ‘Rat! {ank ite plastic T-piece with slightly larger diameter is i ‘available to correct this condition: « replace metal T:piece with white plastic version © remove flow restrictor from inlet fiting of heater valve 19.10 oe "1963-1985 [_ water-cooled |Engine-Cooling System 19 ‘cAUTION, Cootarvantifraeze must not be reused when replacing engine, cylinder head. cylinder head 2st, radiator and healer cove. ATF cooler for Breather valve ‘pea to Til eaatant s s | From |) nest exchanger Theanostt / , me e titan ‘note minkmax markings | 1s Water-cooted trom 1986 | csoingaynom 19.1319 Engine-Cooling System OQ \ BN % \ ( - zonmcsnin “> \ x s Po (ie 2 / 7 ; 19.14 conanEngine-Cooling System 19 Fia.4 Coolant system, draining — open coaiant expansion tank cap. — drain coolant at drain plugs 1.09 cylinder heads: — pinch coolant hoses with hose clamp (Alogal supply) (arraws) betore removing Fig. 3 Coolant system, draining — In case that coolant noses 1 and 2 tor heat exchanger have to be removed, pinch hoses with hose clamp (A-jocal supply) Draining - From 1986 —cloge hose 4 from radiator to thermostat with hose clamp — clase hese 2 from heat exchanger to coolant pipe with hose clamp —loosen nose clamp 1, close hose 2 from radiator to distribution piece with hose clamp — close hose 3 trom heat exchanger to distribution plece with hose clamp = drain coolant at drain plugs (Fig. 1) * save coolant for reuse [see caution] open coolant expansion tank cap CAUTION Coclantiantireeze must not be reused when replacing engine, cylinder head, eylinaer head gasket, adiator and healer core. cooing sistem. caningnning 19,1519 Engine-Cooling System Fig. 4 Hose epring clamp, removingfnstaling — use universal pilers or bose clamp: pliers to remove of install clamp (arrow) Cooling system, tilling ~ set heater control te snaximum heating = open control valve for auxiliary heater under rear seat — remove radiator grille — raise vehicle approx. 10m (4in) al front andar cross-member with aor jack and wooden support or ‘equivaient open bioader serew (arrow) on radiator have up to two gallons of ‘pre-mixed coolant on hang Fig. Cooling system, filing — open blegder valve in engine ‘compartment ‘Azopen B=closed Fig. 7 Cooling system, “ting = fil coolant untit expansion tank is ful (aoprox. 4-5 lires/4,25-6.3 US qi) start engine —at aparox. 2600 rpm, top up tank until ‘coolant flows from bleeder screw on radiator (bubble fr4e), maintain 2000 rpm — close bleeder screw on top of radiator when coolant flows out add coolant until tank is full and close tank with cap, allow engine to fale —tun engine off and lower vehicle —adaitional coolant may need to be added to ‘the expansion tank to top ott 1 | WaRninig— | Hor cootan can scat. Do not romeve expansion tank cap unless angina is cola + Engina must also b9 running at approx. 2000 7m below removing coolant expansion tank cap to prevent loss of ceotat. 19.16 cis sien ning Water-cooled s49Fig. 8 Cooling system, filing —fill refi! tank up to max. mark (arrow) Fig. 8 Cooling system, checking for leaks — attach tester in place of pressure cap * Stant tester SI-255 A, AC-PCTS or ‘equivalent —apply prassure of approx. 1 bar pei) # pressur remains constant, system is OK If pressure drops, look for leaks and eliminate [ Engine-Cooling System 19 Antifreeze hydrometer, checking ‘Cetioration ol hydromoter must be checked ‘requentiy to ensure accuracy. — mix @ 50/50 minture of anbiroeze and water together in a small container — hydrometer should read ~ 35°C (—30°F) nck, Pk 8 mark (pint dot) lo indicate where =85°C (-S0°F) should be. “Anireezs hyaromeler, checkiog ts Water-cooled | cexingerem tna caine 1On TF19 Engine-Cooling System Fig. 10 Expansion tank cap, checking attach cap on tester ‘* Stant toster ST-255 A, AC-PCT-3 or ‘equivalent — apply pressure of 0.9 to 1.15 bar (13-17 psip * if presgure relief valve opens within this range, cap is OK Note ‘Cap has 3 important functions: 1. it opens at pressure of 0:9-1.15 bar (13-17 psi) allowing flow to expansion tank 2. it opens at a vacuum of 0.02-0.1 bar (0.3-1.45 psi) allowing flow from expansion, tank 3. it seals radiator neck Only item t can be checked with testec Wit is suspected that items 2 and 3 are not in order, replace cap Coofent mixture ratio * coolant capacity 17.5 Itr (18.4 US ql) Note Cooling system is filled at factory with mixture of water and antitreezeicorrosion protective solution. Coolant mixture should be used all year. When replacing coolant only use ethylene glycol sd antifreeze (phosphate-rec). Due to higher Bolling point, coolant is an aid to operating cn tull load, particularly in warm climates Outside Tempersture Antifreeze __Weter =25°C(-13°F) 70 Ite 105 ite @4US a) (11 US ah =95°C(-20°F) 875 itr 8.75 ite (@2USq!) @2US q!) 1 9 | 8 Expansion tank cap, checking | Water-cooled Coolant mixture ratioEngine — Cooling System 19 Snap-lock connectors, installing ‘Starting Jan. 1986, the electrical connection on replacement radiator cooling fan motors is now a snap-lock connector. When replacing a fan motor also replace the connector on the wiring hamess. ‘This snap-lock connector was introduced on. Vanagon as a running change during Jan. 1986 production, Note ‘This work procedure willbe applicable when all ‘existing stocks of replacement radiator cooling fan ‘motors with a push-on connector are exhausted. Three wire harness Parts required Tiree pin connector Part No, 191 906 2328 ay Rubber boot Part No. 191 972 6258 ary 2 Terminals Part No. N 902 644 02 ays Work sequence = disconnect vattery ground strap =cut off old connector from wiring harness = push wires through rubber boot = attach terminal to wice — insert wires into connector (cavity numbers on connector) # Red Black to cavity 3 © RedWhite to cavity 2 «© Brown to cavity 1 ~ altach connector to fan motor — attach rubber boot = reconnect battery ground strap = check fan for proper operation Two wire harness Parts required Throe pin connector Part No. 191 906 2328 ty 1 Rubber boot Part No, 191 972 5258 yt Termins Part No, N 902 644 02 Qty 2 ‘Work sequence — disconnect battery ground strap — cutoff old connector from wiring harness ‘— push wires through rubber boot = attach terminal to wire — insert wires into connector (cavity numbers on connector) © RiediBlack to cavity 2 © Brown to cavity 1 — seal cavity 3 with sealer AMVI76 000 05 or equivalent ‘— attach connector to fan motor — attach rubber boot — seal empty wire hole in rubber boot — reconnect battery ground strap — check fan for proper operation ‘CAUTION Part numbers are listed for reference only ‘Always consult with the Parts Department for latest information. snapiocturng comectns,nsang 19.1919 Engine—Cooling System 19.20 =="Hot footwell kit, installing Parts © Cardboard air deflector, left ~delete ‘© Cardboard air deflector, lower —modity ‘© Cardboard air deflector, ower left new part Part No. 251 121 291 © Insulating mat new part Part No. 251 864 249 8 CAUTION Part numbers are for reference only. Aways. check with your Parts Department for latest Parts information = remove radiator grille 2 (three Philips serews-—lower arrows) Engine—Cooling System 19 = pry out air deflector clip (upper arrow) — remove Philips screw from lower apron (lower arrow) = disconnect radiator fan harness connector = remove left cardboard air deflector — reinstall radiator fan harness connector, fresh air Intake trim, and radiator grile — remove spare tire and left spare tre bracket — remove tower cardboard air deflector by removing ‘wo Philips screws (arrows) Fr} Water-cooled vue 19,2119 Engine—Cooling System 0 0 (70-393) — shorten lower cardboard air deflector by 50mm, 20 in) and reinstall ‘* dimension a = 490 mm (19.1 in.) © dimension b = 50 mm (2.0 in) Note Vehicles equipped with air conditioning may already have the lower deflector modiied Vehicles with air conditioning — modify lower lft cardboard deflector © dimension a = 50 mm (2.0 in) push lower lett cardboard air deflector over left longitudinal member (arrow A) and secure behing radiator fan shroud and brake lines (arrow B) ~ reinstall spare tire bracket and spare tre — fold back floor covering 2 from lett side of console = remove 25mm (1.0 in, of backing from self-adhesive insulating mat 1 and apply to floor panel = remove remaining backing and finish applying insulating mat — reinstall floor covering 2 Note It the floor pan continues to heat up, adjust Ventilation ducts so that fresh airs directed to the floor pan, Hot tootwelt kit, Water-cooled 19.22 Instating