Cooling system components, removing and installing

CAUTION:

When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
Ensure sufficient clearance to all moving or hot components.

NOTE:

When the engine is warm the cooling system is under pressure. If necessary release the pressure before beginning repair work.
Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.

Fig 1: Identifying Assembly Tool VAS 5024

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 are recommended for installing spring-type clips.
When installing coolant hoses route them stress-free so that they do not come into contact with other components (observe markings on coolant connection and hose).

Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and V.A.G 1274/9.

Cooling system components, body side

Engine codes: AEG, AVH, AZG, BBW and BEV. Refer to Cooling system components, body side

Cooling system components, engine side:

Engine code: AEG (up to model year 1999). Refer to Cooling system components, engine side

Engine codes: AEG, AVH and AZG (from model year 1999). Refer to Engine codes AEG, AVH and AZG (from model year 1999)

Coolant hose connection diagram. Refer to Coolant hose connection diagram

Engine code: AEG. Refer to Engine code AEG

Engine codes: AVH, AZG, BBW and BEV. Refer to Engine codes AVH, AZG, BBW, BEV

Draining and filling with coolant. Refer to Cooling system, draining and filling

Coolant mixing ratios. Refer to Filling , Draining and filling with coolant