Get Coolingsystem Guide for Volkswagen Fox SUV Second Generation (2003-2021)

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

19 – Cooling system

1

Cooling system components - re‐

move and install

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WARNING

During the works, especially within the engine compartment,

due to the shortage of space, take the following into account:

♦ All hoses (e.g. fuel, hydraulics, activated charcoal filter

system, cooling system and cooling gas, brake fluid, vac‐

uum) and electric cables must be restored to their original

positions.

♦ Provide easy access to all the moving or hot parts.

Note

♦ The cooling system is under pressure when the engine is hot.

Thus, it is necessary to reduce the pressure before doing re‐

pairs.

♦ Hose connection are fastened by spring clamps. When doing

repairs, use spring clamps only.

♦ To remove and install spring clamps, we recommend using the

VAS 5024A or Standart-type clamp pliers -VW 5162- or Pliers

-V.A.G 1921- .

♦ The cooling system hoses should be installed without tension

and without coming into contact with other components (ob‐

serve the marks on the hose connections).

♦ With hot engine, the cooling system is under pressure. Elimi‐

nate pressure before carrying out repairs.

Check for cooling system leaks using the Engine cooling system

tester -V.A.G 1274 - or Engine cooling system tester -VAG 1274B-

with the Adapter -V.A.G 1274/8 - and Adapter -V.A.G 1274/9- .

Cooling system components, body side ⇒ page 53 .

Cooling system components, engine side ⇒ page 54 .

Cooling system - drain and replenish ⇒ page 56 .

Radiator - remove and install ⇒ page 59 .

Water pump - remove and install ⇒ page 60 .

Proportion for coolant mixture ⇒ page 56 .

52

Rep. Gr.19 - Cooling system

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FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.1

Cooling system components on body side

1 - Radiator

❑ Remove and install

⇒ page 59 .

❑ After replacement, ex‐

change all coolant.

2 - Sealing ring

❑ Replace.

3 - Upper cooling system hose

❑ Fixed to the radiator with

retaining clip.

❑ Check for proper seat‐

ing.

❑ Cooling system hose

connection diagram

⇒ page 55 .

4 - Air deflector

5 - 10 Nm

6 - Right radiator fan. -V35-

❑ Vehicles with air condi‐

tioning only.

7 - Retaining clip

❑ Check for proper seat‐

ing.

8 - Support

❑ For Radiator fan -V7- .

9 - Connectors

❑ From cooling system

fans.

10 - Radiator fan -V7-

11 - For cooling system ther‐

mostat valve body

❑ Cooling system hose connection diagram ⇒ page 55 .

12 - Coolant reservoir

❑ Check for cooling system leaks using the Engine cooling system tester -VAG 1274- or Engine cooling

system tester -VAG 1274B- and the Adapter for VAG 1274 -VAG 1274/8- .

13 - Lid

❑ Check with the Engine cooling system tester -VAG 1274- or Engine cooling system tester -VAG 1274B-

and Adapter for VAG 1274 -VAG 1274/9- .

❑ Test pressure 1.4 ... 1.6 bar.

14 - Support

❑ From radiator fan coupling connector -V7- .

15 - Lower cooling system hose

❑ Fixed to the radiator with retaining clip.

❑ Check for proper seating.

❑ Cooling system hose connection diagram ⇒ page 55 .

16 - Thermal switch -F18- , 35 Nm

❑ For Radiator fan -V7- .

1. Cooling system components - remove and install

53

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

Switch temperatures:

❑ Speed 1: on: 95º C; off: 84º C.

❑ Speed 2: on: 102° C; off: 91º C.

17 - Support

❑ For the radiator

❑ Check installation position.

❑ Observe different versions.

18 - 10 Nm

1.2

Cooling system components, engine

side

Thermostat valve body side

1 - 10 Nm

2 - Sealing ring

❑ Replace.

3 - Clip

❑ Check for proper seat‐

ing.

4 - To upper side of radiator.

❑ Cooling system hose

connection diagram.

5 - From lower side of radiator.

❑ Cooling system hose

connection diagram.

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6 - Thermostat valve body

❑ Thermostat valve - Ini‐

tial opening tempera‐

ture 87...102° - final

130°C.

❑ Thermostat valve - Ini‐

tial opening 8 mm - final

12 mm.

7 - Clip

❑ Check for proper seat‐

ing.

8 - For heat exchanger

❑ Cooling system hose

connection diagram.

9 - From the heat exchanger

❑ Cooling system hose

connection diagram.

10 - Cooling system pipe

❑ Cooling system hose

connection diagram.

11 - Sealing ring

❑ Replace.

54

Rep. Gr.19 - Cooling system

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

12 - Engine block water pump housing

13 - 10 Nm

14 - Coolant temperature sensor -G62-

❑ Before removing, eliminate, if necessary, cooling system pressure.

1.3

Cooling system hose connection diagram

1 - Coolant reservoir

2 - Heat exchanger

3 - Lower cooling system hose

4 - Radiator

5 - Upper cooling system hose

6 - Thermostat valve body

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7 - Engine cylinder head / en‐

gine block

8 - Water pump

9 - Cooling system pipe

10 - Intake manifold

1. Cooling system components - remove and install

55

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.4

Cooling system - drain and replenish

Special tools and workshop

equipment required

♦ Refractometer for T 10007

or coolant analysis -EQ

7093-

♦ VAS 5024A or Standart-

type clamp pliers -VW

5162-

♦ Cooling system supply unit

-VAS 6096 -

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1.4.1

Drain

WARNING

Hot vapours may escape from the coolant reservoir when

opening it. Wear protective clothing and goggles to prevent in‐

juries to the eyes and burns. Place a cloth on the cover and

open it carefully.

– Remove lower noise insulation from engine compartment.

– Remove coolant reservoir lid.

56

Rep. Gr.19 - Cooling system

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

– Open the drainage device on the radiator cooling system

-arrow-.

Note

Observe the waste disposal standards!

Checking

Note

♦ Only G 12 may be used as coolant additive, as per “TL VW

774 F” standard Identification feature: lilac colour

♦ Lilac G12, according to “TL VW 774 F” standard, may be mixed

with the previous red G 12 coolant additive!

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♦ G 12 and coolant additives with the “TL VW 774 F” indication

prevent damages caused by freezing and corrosion, as well

as calcareous build-ups and also increase boiling tempera‐

ture. Because of that, the cooling system must be contain

coolant with additive all year round.

♦ Especially in tropical countries, the coolant contributes to the

safe engine operation, when heavily stressed, by elevating

boiling temperature.

♦ Antifreeze protection must be ensured up to around -25°C (in

arctic climate countries, up to -35°C).

♦ Coolant concentration may not be reduced, by adding water,

not even in hot seasons or warm countries. Coolant additive

percentage must be at least 40%.

♦ If, due to climate reasons, further antifreeze protection is re‐

quired, G 12 percentage may be increased, but only up to 60%

(antifreeze protection of around -40°C), otherwise, this pro‐

tection is reduced again and hinders cooling efficiency.

♦ If radiator, heat exchanger, engine cylinder head or engine

cylinder head gasket have been replaced, do not apply the

used coolant again.

Recommended mixture proportion:

Antifreeze Antifreeze G 12 (l)

G 12 Water (l) Water

5)

up to

percent‐

age

(gal)⁵⁾

-13 °F

-31 °F

40 %

50 %

2,25 l 0,59 gal 3,35 l 0,88 gal

2,8 l 0,74 gal 2,8 l 0,74 gal

5) The coolant volume may vary according to the equipment on each vehicle.

– Close the drainage device for the cooling system -arrow-.

– Install engine compartment lower noise insulation.

1. Cooling system components - remove and install

57

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.4.2

Refill

With Cooling system supply unit -VAS 6096-

– Fill cooling system circuit with Cooling system supply unit -

VAS 6096- : ⇒ Instructions for using cooling system supply

unit near VAS 6096.

Without the Cooling system supply unit -VAS 6096-

– Fill with coolant up to the max. mark on the coolant reservoir.

With or without Cooling system supply unit -VAS 6096-

– Close the coolant reservoir.

– Turn off heating command.

– Operate the engine and keep engine speed for 3 minutes at

approx. 2000 rpm.

– Let the engine running until starting the Radiator fan -V7- op‐

eration.

WARNING

Hot vapours may escape from the coolant reservoir when

opening it. Wear protection goggles and clothing to prevent in‐

juries to the eyes and burns. Place a cloth on the cover and

open it carefully.

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– Check coolant level, and if necessary, add more coolant.

When the engine is hot, the level of coolant in the reservoir

must be in the max. mark; when it is cool, in the medium level,

between min. and max. marks.

58

Rep. Gr.19 - Cooling system

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

1.5

Radiator - remove and install

Special tools and workshop

equipment required

♦ Refractometer for T 10007

or coolant analysis -EQ

7093-

♦ VAS 5024A or Standart-

type clamp pliers -VW

5162-

♦ Torque wrench - 5 to 50 Nm

(enc. 1/2") -VAG 1331-

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1.5.1

Removal

– Put front panel in the work position: ⇒ Body - external assem‐

bly works; Rep. Gr. 50 ; Body - front part

– Drain the cooling system ⇒ page 56 .

– Loosen cooling system hoses from radiator

– Disengage the connectors from the Radiator fan thermal

switch -F18- and from the Radiator fan -V7- .

– Remove radiator securing scrrews and remove radiator with

Radiator fan -V7- from below.

Vehicles with air conditioning

Observe additional indications and installation works

1. Cooling system components - remove and install

59

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

Note

To prevent damages to the condenser, as well as to the cooling

gas pipes, it is necessary to ensure the hoses are not stressed,

bent or deformed.

– Loosen cooling gas pipes brace(s).

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– Loosen radiator condenser and fasten it to the front panel.

1.5.2

Installation

Install in reversed order, considering the following:

Fill cooling system ⇒ page 56 .

– Electrical connections and installation: ⇒ Current flow dia‐

grams, Electrical fault finding and Fitting locations.

1.6

Water pump - remove and install

60

Rep. Gr.19 - Cooling system

FOX 2004 ➤

3 - Cyl. injection engine - Edition 12.2009

Special tools and workshop equipment required

♦ Refractometer for T 10007 or coolant analysis -EQ 7093-

♦ VAS 5024A or Standart-type clamp pliers -VW 5162-

♦ Torque wrench - 5 to 50 Nm (enc. 1/2") -VAG 1331-

Water pump wrench -VAG 1590-

– Due to changes in water pump pulley fastening bolts, file the

three round shoulders at least: -a = 1 mm-.

Note

♦ Water pump integrated gasket may not be separated from the

pump.

♦ In case of damages and leaks, replace the entire pump to‐

gether with the gasket.

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1.6.1

Remove

– Drain the cooling system ⇒ page 56 .

– Remove the Poly-V belt ⇒ page 13 .

– Remove water pump pulley.

– Remove water pump fastening bolts.

– Remove water pump

1.6.2

Installation

Install in reversed order, considering the following:

– Install the crankcase water pump.

– Tighten the fastening screws with 25 Nm.

– Tighten water pump pulley fastening bolts to 20 Nm.

– Install Poly-V belt ⇒ page 13 .

– Fill cooling system ⇒ page 56 .

1. Cooling system components - remove and install

61

Coolingsystem for Your Volkswagen Fox SUV Second Generation (2003-2021)

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