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    8 views12 pages

    Cooling System Diagnostics Pgs 19-1 Thru 19-12 PDF

    Uploaded by

    Wawan Satiawan

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 12
    ENGINE—COOLING SYSTEM _19-1 Engine—Cooling System 2194 2192 Coolant, pump and thermostat . 2192 Radiator and cooling fan 2193 Coolant temperature/lovel warning lights ..... 19-4 ‘TROUBLESHOOTING 19-4 Diagnostic checks. . 2196 Coolant/antifreeze concentration, testing . 2196 Cooling system, pressure testing ........... 196 Cooling fans and thermoswitch, testing . ..... 19-7 Engine cootant temperature sensor, testing .. . 19-9 ‘Thermostat, testing... 19-10 Coouine System, DRAINING AND FILLING. ...........22.-. 1911 COOLING SYSTEM COMPONENTS (4-CYLinDER) . Cooling system, components (1.8L) Coolant pump, replacing (1.8L). Cooling system, components (1,91, code: ALH)..-....- Cooling system, components (1.81, code: BEW) .. - 1916 Coolant pump, replacing (1.9L) . 1947 Cooling system, components (2.0L) . 19.18 Coolant pump, replacing (2.0L) . 1919 Radiator and cooling fans, assembly (1.8L). . 19-20 Radiator and cooling fans, assembly (1.9L72.0L) 5 =19-21 Radiator and cooling fans, removing and instaling (4-cylinder) 19-22 ‘Thermostat, replacing (4-cylinder)........,-1923 COOLING SYSTEM COMPONENTS (6-Cunver).. 19:24 Cooling system components (2.5L) --19-24 Cooling system components ‘on upper chain guard (2.51) .. =19-24 Coolant pump, replacing (2.5L) ... 19-26 Radiator and cooling fans, assembly (2.5L). . 19-30, Radiator, removing and installing (2.6L) .....19-31 ‘Thermostat, removing and installing (2.5L) . . 19-32 ‘TABLES . Cooling system troubleshooting 19-5; GENERAL ‘This section covers repairs and troubleshooting forthe en ‘gine cooling system. For heater core and related heating and ar: ‘components, see 80 Heating and Air Conditioning. For information on the engine oil cooler, see ‘17 Engine-Lubrication. For information on the ATF cooler ‘used on vehicles with automatic transmissions, see 37 Au- [Engine [Engine code at yinrbo gasine [APH Aw, AW, KF, NU HC &eyindor TI cot [Aun ew ot oyinergascine [AEG, AVE AZG, [p00 Bev, BaD [25 Seyi gascine BPR, BPS LEER TT 19-2 _ENGINE—COOLING SYSTEM Warnings and cautions “The following wamings and cautions should be observed when working on the cooling system. WARNING — + Hot coolant can scald and recut in eorfous por: ‘sonal injury. Do not work on the cooing system una it has tty cooled. ‘*Atnormal operating temperature the cooling sys {om Is prossurlzed. Alow the systom to cool as {ong as possible before opening, a minimum ofan ‘hour, thon release the cap siomiy to afow safe re- ease ofthe pressure WARNING — ‘= Releasing the cooing system pressure lowers the coolants boing point, and the coolant may boil suddenly. Use heavy gloves and wear eye and face protection to guard against scaing. + Use exrome care when working ator near the ra- ‘diator cooling fans when the angine Fe hot. The fan can come on at any time, even Ifthe ignition ey is switched oft “Use exreme care when draining and dsposing of ‘engine coolant. Coolant is poisonous and lethal, ‘Chiron and pets are atracted 10 coolant be- ‘cause offs woot mel and last, Soe a doctor (or veterinarian inmodiataly Wany amount of cool- anti ingested. ' + Disposal of used coolant must be dane in con Jormance with al appicable local, state and fed- ‘eral laws. Do not pour into the ground or down drains or sewers. Contamination of ground water wi recut ‘CAUTION — ‘Avoid adking cold water to tre cooling systom ‘while the engine is hot or overheated. is nec- ‘essary fo adel coolant oa hot system, do so only withthe engine runing and the coolant pump op erating. Coolant, pump and thermostat Volkswagen uses only phosphate and silicate tree ant- {freeze/coolant. When supplied by Volkswagen, this cool ant is known as G12 (red color) or G12+ (purple color) Duo toits special characteristics the G12 or @12+ coolant should never be mixed with G11 (green coolant). See 03 Maintenance for additional information and cautions. For best overall performance, the coolant additive pro- portion must be at least 40%, but not more than 60% to ‘maintain the antifreeze protection and cooling efficiency. Distiled water should always be used due to the various ‘chemicals and minerals usually associated with tap wa- (©2007 Beta com- AEE rowed ENGINE—COOLING SYSTEM __19-3 ‘er. Under no circumstances should 100% coolantant- ‘reaze be used. This will generally result in overheating ‘and poor heater operation due to the poor heat transfer ‘characteristics of pure antifreeze. For accurate testing of _antireeze/coolant protection, a refractometer such as |W tool CEN5021 should be used, see Coolantanti- {freeze protection, testing. A 50/50 mixture is generally preferred and will provide freeze protection to-34°F (37°0). ‘An impeller-type cootant pump is mounted into cylinder block. The pump is crankshafi-driven by the same ‘toothed bolt that drives the camshaft and circulates cool- nt through the system whenever the engine is running. “The thermostat controls coolant flow through the radiator. ‘When the engine is cold, the thermostat restricts flow through the radiator to allow the engine to reach operat- ing temperature quicker. As the engne heats up, the ther- mostat opens and coolant circulates through the whole system, including the radiator. Radiator and cooling fan ‘Aradiator cooting fan assembly provides auxiliary ar tlow ‘through the radiator. The fan assembly is electrically op- ‘erated and thermostatically controlled so that it runs only When extra airflow is required to maintain proper coolant ‘temperature. “The radiator isa cross-flow design constructed of an alu- ‘minum core and plastic side tanks. A translucent expan- sion tank, oF overflow reservoir, provides for the expansion of the coolant at higher temperatures, easy ‘monitoring ofthe coolant level and a convenient location for adding coolant. ‘An electric radiator cooling fan assembly is controlled by athermoswitch located in the side ofthe radiator. Athigh- € coolant temperatures, the switch closes to start the cooling fans. Any time the coolant temperature rises to higher than normal tevels, the fan will star and continue {to run until coolant temperature retums to a normal range. On vehicles with air conditioning, rising refrigerant pressures will also activate the cooting fans. WARNING — The electric cooing fans can come on at any time, ‘ven ifthe key is out of tho fn. To avoid person al injury, use extreme caution when werking at or (©2007 Bender cort-AR ard sibsersilalicitats 19-4 _ENGINE-COOLING SYSTEM oo Coolant temperature/level warning lights * tre Now Bootie snot equipped with a conventional coolant temperature gauge. In place of the gauge ls & ‘symbol on the instrument cluster (arrow) that changes loro provide nfrmation about cooling system opera- ton. saree ‘The coolant temperature and level symbol will change ‘color to incicate the following cooling system functions: + Steady BLUE ‘May come on when the engines first started to indicate ‘cold engine, + Flashing BLUE ‘Comes on to indicate a malfunction within the electrical ‘section of the coating system. + Steady RED ‘Comes on when the ignition le first ewitched on as a {functional check and sel-test, flashes several times ‘and goes out. ‘+ Flashing RED ‘Comes on when driving to indicate a low cootant level ‘condition or an overheat situation. A warring buzzer ‘may also sound. Pull vehicle to side of road as soon as possible and determine cause of warning fight. + Not iluminated (no fight) {self testis OK, no light indicates normal cooling sys- tem operation. ‘The coolant temperature and level waming lights have ‘Onboard Diagnostic (BD) capabilites included with the

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