Volkswagen Jetta 2000 User manual

Cooling system components, removing and installing
Coolant fans (V7 and V35), checking
Coolant feed pump (V51), checking
Coolant hoses, connection diagram
Coolant pump, removing and installing
Coolant, draining and filling
Cooling system components, body side
Cooling system components, engine side
Radiator, removing and installing
Thermostat housing, disassembling and assembling
Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
19 Engine-Cooling system (Page GR-19)

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-1)
Notes:
The cooling system is under pressure when the engine is warm. Release pressure
before making repairs.
The hose connections are fastened with spring band clips and rapid action hose
couplings. Only use spring band clips when making repairs.
The pliers V.A.G 1921 are recommended for assembling the spring band clips.
While installing, lay the hoses somewhat slack while being careful that they do not
come in contact with other components (pay attention to the markings on the
connector and hose).
Test whether the cooling system is seal-tight using the test instrument V.A.G 1274 and the
adapters V.A.G 1274/8 and V.A.G 1274/9.
Cooling system components, body side page 19-2.
Cooling system components, engine side page 19-7.
Thermostat housing, disassembling and assembling page 19-13.

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-2)
Cooling system components, body side
Main radiator
Auxiliary radiator page 19-5
1 - Radiator
Removing and installing page 19-19
After replacement, refill completely with new coolant
2 - O-Ring
Replace if damaged
3 - Upper coolant hose
Fastened to radiator with rapid action hose coupling
Ensure tight fit
Coolant hoses, connection diagram page 19-11
4 - Air scoop
5 - 10 Nm
6 - Coolant fan (V7)

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-3)
7 - Fan bracket
8 - Retaining clamp
Check for tight fit
9 - Connector
10 - Coolant fan (V35)
11 - Bracket
For fan connector
12 - Lower coolant hose
Fastened to radiator with rapid action hose coupling
Ensure tight fit
Coolant hoses, connection diagram page 19-11
13 - O-Ring
Replace

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-4)
14 - Thermo switch (F18), 35 Nm
For electric fan
Switching temperatures, 1st stage:
On: 92-97 C
Off: 84-91 C
Switching temperatures, 2nd stage:
On: 99-105 C
Off: 91-98 C
15 - Bracket
For radiator
Observe install position
16 - 15 Nm

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-5)
Auxiliary radiator
1 - 10 Nm
2 - Retaining frame
For auxiliary radiator
3 - Spacer sleeve
4 - Rubber disk
5 - Lower bolt, 10 Nm
6 - Air scoop
Clip into retaining frame
7 - Auxiliary radiator
For vehicles in hot climates
Removing and installing page 19-19
After replacement, refill completely with fresh coolant
8 - 5 Nm

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-6)
9 - To Y-branch of upper coolant hose
Coolant hoses, connection diagram page 19-11
10 - To Y-branch of lower coolant hose
Coolant hoses, connection diagram page 19-11
11 - Bracket
For auxiliary radiator

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-7)
Cooling system components, engine side
1 - Pressure cap
Check with V.A.G 1274 test instrument and V.A.G 1274/9 adapter
Test pressure 1.4-1.6 bar
2 - O-Ring
Replace if damaged
3 - Coolant recovery bottle
Check for leaks in cooling system using V.A.G 1274 test instrument and
V.A.G1274/8 adapter
4 - 10 Nm
5 - Upper coolant pipe
Clipped into the bulkhead
Coolant hoses, connection diagram page 19-11

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-8)
6 - To heat exchanger
Coolant hoses, connection diagram page 19-11
7 - Throttle valve control unit (J338)
Heated by coolant
8 - To upper coolant hose
Coolant hoses, connection diagram page 19-11
9 - To upper radiator
Coolant hoses, connection diagram page 19-11
10 - Gasket
Replace
11 - To lower radiator
Coolant hoses, connection diagram page 19-11

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-9)
12 - Thermostat housing
Disassembling and assembling page 19-13
13 - Coolant feed pump (V51)
Check page 19-24
14 - From heat exchanger
Coolant hoses, connection diagram page 19-11
15 - 25 Nm
16 - Oil cooler
Coat contact surfaces outside of sealing ring with AMV 188 001 02
Ensure free movement among surrounding components
See Note page 17-1
17 - Screw plug
18 - Coolant pipe
Coolant hoses, connection diagram page 19-11

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-10)
19 - Coolant pump
Observe install position
Check for smooth running
Replace completely if damaged or if leaking
Removing and installing page 19-30
20 - 15 Nm
21 - Pulley
For coolant pump
22 - 25 Nm
23 - To Y-branch of heat exchanger/coolant feed pump
Coolant hoses, connection diagram page 19-11

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-11)
Coolant hoses, connection diagram
1 - Coolant recovery bottle
2 - Upper coolant pipe
3 - Throttle valve control unit (J338)
4 - Heat exchanger for heating
5 - Check valve
6 - Coolant feed pump (V51)
7 - ATF radiator
Only vehicles with automatic transmission
8 - Upper coolant hose
9 - Radiator
10 - Lower coolant hose

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-12)
11 - Thermostat housing
12 - Lower coolant pipe
13 - Oil cooler
14 - Auxiliary radiator
15 - Coolant pump
16 - Cylinder block
17 - Cylinder head

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-13)
Thermostat housing, disassembling and assembling
Notes:
Routing of hoses at the coolant controller housing page 19-7.
1 - Plug
2 - O-Ring
Replace
3 - Gasket
Replace
4 - Retaining clamp
Check for tight fit
5 - Thermostat housing
6 - 10 Nm

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-14)
7 - Thermostat
Install position: large plate downward
Checking: heat controller in water bath
Opening starts at approx. 80 C
Opening ends at approx. 105 C
Travel at least 7 mm
8 - Connector
9 - 10 Nm
10 - Coolant temperature sensor (G62)
With coolant temperature display sensor (G2)
For engine control unit
If necessary, release pressure from cooling system before removing
Checking:
Repair Manual, 2.8 Liter VR6 OBD II Fuel Injection & Ignition , Repair Group 01

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-15)
Coolant, draining and filling
Special tools, equipment, test and inspection devices; required accessories
V.A.G 1306 Drip pan
V.A.G 1921 spring band clip pliers
Hydrometer

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-16)
Draining
- Open the coolant recovery bottle cap.
- Remove damping pan:
Repair Manual, Body-Exterior , Repair Group 50
- Unscrew the drain plug -arrow- from the radiator return to drain the coolant from the
radiator.
- Also pull the coolant hose out from the oil cooler -arrow- to drain the coolant from the
engine.
Notes:
Please follow regulations for disposal!

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-17)
Refilling
Notes:
To satisfy TL VW 774 D, only G 12 may be used as a coolant additive. Color coding:
red.
Never mix G 12 with any other coolant additives!
If the liquid in the coolant recovery bottle is brown, this means that G 12 was mixed
with another coolant and the coolant has to be changed.
G 12 and additives which are labeled "satisfies TL VW 774 D" prevent damage from
freezing and corrosion and prevent lime deposits. They also raise the boiling point.
For these reasons, the cooling system must be filled with antifreeze and anti-
corrosion agents throughout the year.
The coolant's higher boiling point will contribute to operational reliability under higher
engine loads, especially in tropical climates.
The antifreeze protection must go down to -25 C (in Arctic climates down to -35 C).
The concentration of the coolant may not be reduced by topping up during the warm
seasons or in warm countries. The proportion of additive must be at least 40%.
If the climate requires stronger antifreeze protection, the portion of G 12 can be
increased, but never above 60% (antifreeze protection down to about -40 C),
otherwise the antifreeze protection will begin to decrease again and the cooling
effect will be reduced.
Do not reuse the same coolant if the radiator, heat exchanger, cylinder head or
cylinder head gasket have been replaced.

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-18)
Recommended mixing ratios:
1) The amount of coolant may vary depending on the vehicle accessories.
- Tighten the drain plug into the radiator return.
- Push the coolant hose onto the oil cooler connection and pull it tight.
- Fill with coolant up to the upper mark on the cross-hatched area on the coolant
recovery bottle.
- Close coolant recovery bottle.
- Expose the heater controls and turn-off the air conditioning if necessary.
- Start the engine and run at approximately 2000 rpm for about 3 minutes.
- Keep engine running until fan starts.
- Check coolant level and fill as necessary.
- The coolant level must be within the cross-hatched region when the engine is
running warm. It must be above the lower mark if the motor is cold.

Volkswagen Jetta, Golf, GTI 1999, 2000
2.8 Liter VR6 2V Engine Mechanical, Engine Code(s): AFP
Cooling system components, removing and installing (Page 19-19)
Radiator, removing and installing
Special tools, equipment, test and inspection devices; required accessories
V.A.G 1306 Drip pan
V.A.G 1331 Torque wrench (5-50 Nm)
V.A.G 1921Pliers for spring band clips
Hydrometer