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  #1  
Old 11-30-2010, 08:14 PM
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NewBeetleMechanicRegistered Member NewBeetleMechanic is offline
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Default Cooling system issues: Information topic.

It is possible to have a Check Engine Light (CEL) and a number of Coolant Temperature Sensor (CTS) codes set due to the overheat condition caused by the faulty water pump impeller. Likely associated codes are P0125, P0116 and P0117. When refilling the cooling system, never mix the VW G12 non-phosphate/non-silicate factory coolant with a standard type ethylene/glycol coolant.


A.

1. Check the actual temperature of the radiator and compare it to the temperature of the cylinder head.

2. If the radiator remains significantly cooler than the cylinder head, or if no coolant flow is evident in the cooling system, check the water pump impeller for damage, missing fins or spinning on the water pump shaft.

3. The water pump impeller is plastic and can crack or loosen, allowing the water pump shaft to freely spin without moving the impeller. Insufficient water flow through the cooling system, due to the faulty impeller, will cause an overheat condition.

4. It is possible to access the water pump impeller by removing the thermostat and thermostat housing. The impeller must not spin on the shaft, or have missing pieces.


Affected models:

1995 Volkswagen Jetta III GL 2.0L, Vin C 2002 Audi A4 1.8L, Vin C, Turbo, Eng Cfg L4, Eng Des AMB
1996 Volkswagen Golf Harlequin 2.0L 2002 Audi A4 Quattro 1.8L, Vin C, Turbo, Eng Cfg L4, Eng Des AMB
1996 Volkswagen Jetta GLS 2.0L, Vin B 2002 Volkswagen Beetle 1.8L, GAS, Turbo, Eng Des AWV
1997 Volkswagen Jetta GLS 2.0L, Vin A 2002 Volkswagen Beetle 2.0L, GAS, Eng Des AVH
1998 Volkswagen Beetle 2.0L, GAS, Vin B, Eng Des AEG 2002 Volkswagen Golf GTI 1.8L, Turbo, Eng Cfg L4, Eng Des AWP
1999 Audi A4 1.8L, Vin B, Turbo, Eng Cfg L4, Eng Des AEB, USA/Canada 2002 Volkswagen Jetta GLS Wagon 1.8L
1999 Volkswagen Beetle 2.0L, GAS, Eng Des AEG 2002 Volkswagen Passat 1.8L, Turbo, Eng Cfg L4, Eng Des AWM
1999 Volkswagen Golf GLS 2.0L 2003 Volkswagen Beetle 1.8L, GAS, Turbo, Eng Des AWV, USA/Canada
1999 Volkswagen Jetta GLS 2.0L, Vin A, Eng Cfg L4, Eng Des ABA, USA/Canada 2003 Volkswagen Beetle 2.0L
1999 Volkswagen Jetta GLS 2.8L, Eng Cfg V6, Eng Des AFP, USA/Canada 2003 Volkswagen Golf 2.0L
1999 Volkswagen Passat 1.8L, Turbo, Eng Cfg L4, Eng Des AEB 2003 Volkswagen Golf GTI 1.8L, Turbo, Eng Cfg L4, Eng Des AWP
2000 Volkswagen Beetle 1.8L, GAS, Turbo, Eng Des APH 2003 Volkswagen Jetta GL 1.8L, Turbo, Eng Des AWP, USA/Canada
2000 Volkswagen Beetle 2.0L, GAS, Eng Des AEG 2003 Volkswagen Jetta GL 2.0L
2000 Volkswagen Jetta GL 2.0L 2003 Volkswagen Jetta GL 2.0L, Eng Des AZG, USA/Canada
2000 Volkswagen Jetta GLS 2.0L, Eng Cfg L4, Eng Des AEG 2003 Volkswagen Jetta GLS 2.0L, Eng Cfg L4, Eng Des AVH, USA/Canada
2001 Volkswagen Beetle 2.0L, GAS, Eng Des AVH 2003 Volkswagen Jetta GLS Wagon 1.8L
2001 Volkswagen Golf GTI 1.8L, Turbo, Eng Cfg L4, Eng Des AWW 2003 Volkswagen Passat 1.8L, Turbo, Eng Cfg L4, Eng Des AWM
2001 Volkswagen Jetta GL 2.0L, Eng Des AEG 2004 Volkswagen Jetta 1.8L
2001 Volkswagen Jetta GLS 1.8L, Turbo, Eng Cfg L4, Eng Des AWD 2004 Volkswagen Jetta 1.8L, Turbo, Eng Cfg L4, Eng Des AWP, USA/Canada


B.


The fans contain the resistor for low speed operation and the common failure is the resistor. A common question is why did both fans fail at the same time and most likely they did not. Usually one fan failed first but there was no symptom until the second fan failed, at which time it was discovered that both fans do not operate.

1. Check the temperature of the thermal switch, mounted in the bottom of radiator, and verify that it is reaching proper temperature. The thermal switch will close terminals 1 and 2 at 190 degrees Fahrenheit, terminals 2 and 3 will close at 210 degrees Fahrenheit.

2. If temperature is not getting hot enough at the fan switch in the radiator, check the temperature at the engine. If the engine is not getting hot, replace the thermostat, (stuck open). If the engine is getting hot, check for either a stuck closed thermostat or faulty impeller in the water pump.

3. If the temperature at the switch is hot enough but the fans do not turn on, check for power of 12 volts at the thermal switch terminal 2 (Red wire). If no power, check fuse S180 (30 amp) at the battery auxiliary fusebox.

4. With the connector unplugged, bridge terminals 2 and 1. Low fan speed should occur. With the bridge still installed, bridge terminals 2 and 3. High speed fan should occur. If both fans do not come on both speeds, test for 12 V and a good ground at the fans and replace as needed.


Affected models:

1998 Volkswagen Beetle 2.0L, GAS, Vin B, Eng Des AEG 2001 Volkswagen Beetle 2.0L, GAS, Eng Des AVH
1999 Volkswagen Beetle 2.0L, GAS, Eng Des AEG 2001 Volkswagen Golf GTI 2.8L, Eng Cfg V6, Eng Des AFP
1999 Volkswagen Jetta GL 2.0L, Eng Des ABA 2001 Volkswagen Jetta GLS 2.8L, Eng Cfg V6, Eng Des AFP
1999 Volkswagen Jetta GL 2.0L, Eng Des AEG 2001 Volkswagen Jetta GLX 2.8L
1999 Volkswagen Jetta GLS 2.0L, Eng Cfg L4, Eng Des ABA, USA/Canada 2002 Volkswagen Cabrio 2.0L
2000 Volkswagen Beetle 1.8L, GAS, Turbo, Eng Des APH 2002 Volkswagen Golf GTI 1.8L, Turbo, Eng Cfg L4, Eng Des AWP
2000 Volkswagen Beetle 2.0L, GAS, Eng Des AEG 2002 Volkswagen Jetta GLS 2.0L, Eng Cfg L4, Eng Des AVH
2000 Volkswagen Golf 2.0L, GAS, Eng Des AEG 2002 Volkswagen Jetta GLS Wagon 1.8L
2000 Volkswagen Jetta GLX 2.8L 2003 Volkswagen Golf 2.0L
2001 Volkswagen Beetle 1.9L, DIESEL, Turbo, Eng Des ALH 2003 Volkswagen Golf GTI 1.8L, Turbo, Eng Cfg L4, Eng Des AWP


C.

When refilling the cooling system, never mix the VW G12 non phosphate/non silicate factory coolant with a standard type Ethylene/Glycol coolant. A quick check that can be performed to gauge cooling system flow is to raise engine to 2500 RPM and coolant should be steadily flowing from the small bypass hose into the plastic coolant reservoir.

1. Check the actual temperature of the radiator and compare it to the temperature of the cylinder head.

2. If the radiator remains significantly cooler than the cylinder head, check the water pump impeller for damage, missing fins or spinning on the water pump shaft. The water pump impeller is plastic and can crack or loosen, allowing the water pump shaft to freely spin without moving the impeller. Insufficient water flow through the cooling system due to the faulty impeller will cause an overheat condition.

3. The cooling fans will not come on due to low coolant flow because the fan thermo switch is located in the lower left of the radiator and will not get hot enough for fan operation before the engine overheats.

Affected models:

1998 Audi A4 Quattro 1.8L, Vin B, Turbo, Eng Cfg L4, Eng Des AEB, USA/Canada 2002 Volkswagen Jetta GLS Wagon 1.8L
1998 Volkswagen Beetle 2.0L, GAS, Vin B, Eng Des AEG 2002 Volkswagen Passat 1.8L, Turbo, Eng Cfg L4, Eng Des AWM
1999 Volkswagen Beetle 1.8L, GAS, Turbo, Eng Des APH 2003 Audi A6 Quattro 4.2L, Vin L, Eng Cfg V8, Eng Des AWN
1999 Volkswagen Jetta GL 2.0L, Eng Des ABA 2003 Volkswagen Beetle 1.8L, GAS, Turbo, Eng Des AWV, USA/Canada
2000 Volkswagen Beetle 1.8L, GAS, Turbo, Eng Des APH 2003 Volkswagen Jetta GL 2.0L
2000 Volkswagen Jetta GLS 2.8L, Eng Cfg V6, Eng Des AFP 2003 Volkswagen Jetta GLS 2.0L, Eng Cfg L4, Eng Des AVH, USA/Canada
2001 Audi TT Quattro 1.8L, Vin X, Eng Des AWP 2003 Volkswagen Jetta GLS Wagon 1.8L
2001 Volkswagen Beetle 1.8L, GAS, Turbo, Eng Des AWV 2004 Audi A4 Quattro 1.8L, Vin C, Turbo, Eng Cfg L4, Eng Des AMB
2001 Volkswagen Beetle 2.0L, GAS, Eng Des AZG 2004 Volkswagen Beetle Turbo S 1.8L
2001 Volkswagen Jetta GLS 1.8L, Turbo, Eng Cfg L4, Eng Des AWD 2004 Volkswagen Golf GTI 1.8L, Turbo, Eng Cfg L4, Eng Des AWP
2001 Volkswagen Passat 1.8L 2004 Volkswagen Jetta 1.8L
2001 Volkswagen Passat 1.8L, Turbo, Eng Cfg L4, Eng Des AWM, USA/Canada 2004 Volkswagen Jetta 1.8L, Turbo, Eng Cfg L4, Eng Des AWP, USA/Canada
2001 Volkswagen Passat 2.8L, Vin H, Eng Cfg V6, Eng Des ATQ, USA/Canada 2004 Volkswagen Jetta 2.0L, Eng Cfg L4, Eng Des BBW, USA/Canada
2002 Audi A6 Quattro 4.2L, Vin L, Eng Cfg V8, Eng Des AWN 2004 Volkswagen Jetta 2.0L, Eng Cfg L4, Eng Des BEV, USA/Canada
2002 Audi TT Quattro 1.8L, Vin T, Eng Des AMU 2004 Volkswagen Jetta GLS 2.0L, Eng Cfg L4, Eng Des BBW, USA
2002 Volkswagen Golf 2.0L, GAS, Eng Des AVH, USA/Canada 2004 Volkswagen Passat 1.8L, GAS, Turbo, Eng Cfg L4, Eng Des AWM, USA/Canada
2002 Volkswagen Jetta GL 2.0L, Eng Des AZG 2005 Audi A4 2.0L, Vin F, Turbo, Eng Cfg L4, Eng Des BPG
2002 Volkswagen Jetta GLS 2.0L, Eng Cfg L4, Eng Des AVH 2005 Audi TT 1.8L
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  #2  
Old 11-30-2010, 08:34 PM
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Obviously a cut and paste...but good info.

For the record, G12 is best. But in a pinch, Zerex G-05 can be mixed with G12 without any issue. It is the same type of coolant.
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Old 11-30-2010, 08:43 PM
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NewBeetleMechanicRegistered Member NewBeetleMechanic is offline
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Default

Quote:
Originally Posted by DZLBUG View Post
Obviously a cut and paste...but good info.

For the record, G12 is best. But in a pinch, Zerex G-05 can be mixed with G12 without any issue. It is the same type of coolant.
Thank you for adding this before I finished this topic.


It was a cut and paste, from a site for just VW Factory mechanic's (which is not accessable to you people). This information I have already reviewed, years ago.


Once complete this topic will be a total cooling system diagnostic guide.
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  #4  
Old 12-02-2010, 08:44 PM
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ZannRegistered Member Zann is offline
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Car: 2002 New Beetle Turbo S
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Quote:
Originally Posted by NewBeetleMechanic View Post
Once complete this topic will be a total cooling system diagnostic guide.
You seem to be deleting your guides faster than you post them. Already, several favorite links of yours have vanished.
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