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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKIV-A4 TDIs (VE and PD)

VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old May 28th, 2007, 07:57   #1
cattlerepairman
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Default coolant leak question

I have a coolant leak. I tracked coolant loss due to no time to work on the car; it did not get worse and it does not leak from a "dangerous" location where subsequent damage would be likely, so I just topped up (about one pint per week-10 days).

It drove me nuts to find the exact location. It will not leak at idle, it will not leak with the a/c on (to drive temps up). I could see residue on the block underneath the thermostat housing, so I figured that was it and replaced it. Nope.

Higher rpm and wiggling of hoses finally revealed the location - O-ring #11, where the coolant pipe enters the block: ******WRONG PICTURE!!!! THIS IS THE 1.8 T**** CHECK PIC LOWER IN THE THREAD!****




Now my questions, mainly to figure out how much time I have to set aside to fix it:
  • how is the pipe attached to the block? Is it just pressed in there/snapped in?
  • can I just pull it out (by pulling it to the right side) with the other hoses still attached, or do I have to disassemble everything else that is attached to it? (I have a Beetle, so that is a PITA in that location).
  • ETKA part # for the darn O-ring and the coolant pipe (in case it tuns out to be rusted or leaking at a seam).
Many thanks!
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Last edited by cattlerepairman; December 24th, 2007 at 07:53.
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Old May 28th, 2007, 09:57   #2
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The sealing ring is 037 121 688.

The ring is relatively easy to replace. Drain the coolant. Unplug the coolant temp sensor. There are two bolts that hold the flange in place. If a manual tranny, you will need to remove the vacuum line bracket first. Pull it away from the head, and clean the head area well with scotch brite. Put the O ring in place, and resecure. If it won't pull away far enough, just remove the hose on the front to give you more room. I never remove all the hoses when I remove these for head replacements.

If you need a new flange, there are two different ones for the manual vs auto tranny. You will need a new O ring to bolt the coolant glow plug flange to the coolant flange.

038 121 133A Flange with coolant glowplug
038 121 132C Flange with sealing washer (won't need the sealing ring above)

037 121 687 Sealing washer for glowplug housing

Per ETKA, I can't find out whether the flange for the coolant glowplugs come with the coolant flange. I haven't had to buy one.

Obviously, if you haven't replaced the coolant temp sensor, now would be an excellent time to replace it.

Good luck, Bruce
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Last edited by paramedick; May 28th, 2007 at 10:00.
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Old May 28th, 2007, 10:50   #3
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Bruce,

thanks for the detailed and speedy reply!
I will post, once done.
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Old June 20th, 2007, 10:14   #4
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I've had that flange replaced twice under warranty due to coolant leak. Faulty design ?
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Old June 20th, 2007, 10:23   #5
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I still did not find out the part number for the #11 o-ring; after I had wiggled the coolant pipe enthusiastically to make it leak, it has almost stopped leaking. Currently, I lose maybe a pint in three weeks (down from a pint a week or quicker).
I will eventually get around to it....on the positive side, I have become an expert in judging the coolant level in the reservoir by evaluating the strength of coolant smell upon exiting the car and I am usually ready to top up before the red warning light honks at me.
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Last edited by cattlerepairman; June 20th, 2007 at 10:25.
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Old July 4th, 2007, 23:42   #6
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My car is an 01 Jetta automatic, are the part numbers in this thread correct for my application? I have a leak but I can't take the car apart until I have the replacement parts here. Should I replace the flange and o-ring just to be safe? Sorry to threadjack but I didn't think I should start another for the same problem.
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Old July 5th, 2007, 07:37   #7
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Default cooling sys

Quote:
Originally Posted by copilot
My car is an 01 Jetta automatic, are the part numbers in this thread correct for my application? I have a leak but I can't take the car apart until I have the replacement parts here. Should I replace the flange and o-ring just to be safe? Sorry to threadjack but I didn't think I should start another for the same problem.
For your TDI (2k1 ALH w/auto trans)
coolant flange P/N: 038-121-132-C
O-ring P/N: 037-121-688
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Old July 5th, 2007, 12:32   #8
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I just placed the order at impex. Thanks Herm!
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Old July 5th, 2007, 22:10   #9
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Default Correction

I inadvertently scanned the wrong picture; the pic above is the 1.8T engine.

My leak is where the coolant pipe (#10) is connected to the block; the O-ring in question is #11. It requires a cross-eyed look to place the O-ring into context with the coolant pipe!



The O-ring has the part number N-903-653-02 SEAL and cost $1.40.
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Old July 13th, 2007, 21:36   #10
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Quote:
Originally Posted by cattlerepairman
I

My leak is where the coolant pipe (#10) is connected to the block; the O-ring in question is #11. It requires a cross-eyed look to place the O-ring into context with the coolant pipe!
The O-ring has the part number N-903-653-02 SEAL and cost $1.40.
......and putting it in is a %$%% P.I.T.A.
In order to be able to pull the coolant pipe out of the block far enough to actually get the old O-ring off and the new one on, I had to remove the intake air hose, the coolant flange (with the coolant glow plugs), the turbo oil supply line and brackets (bolted to the coolant pipe and crossing it in a way that makes moving the pipe almost impossible; I did not remove the fitting on the turbo, though), the dipstick tube and several coolant hoses attached to the pipe and the flange. Be very, very careful with the turbo oil supply line, do not twist it and do replace both copper washers at the banjo bolt!!

I used blue gasket maker on the end of the pipe as well, just to be sure.

Test drove, filled up with more 50:50 coolant - so far so good. I also had to replace the door lock module and a rear wheel bearing. When it rains, it pours!
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Last edited by cattlerepairman; October 22nd, 2010 at 11:50.
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Old August 16th, 2007, 09:54   #11
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I think I have the exact same leak. There is pink residual down there and I can't see an obvious leak, but the coolant level drops very gradually to the minimum mark. How did your repair work out?
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Old November 25th, 2007, 09:02   #12
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I've got the exact same problem. I posted an inquiry two days ago in the "tdi 101" forum entitled "possible coolant leak?" and in my impatience googled "coolant leak beetle" and found this thread. Amazing.

How did it work out?
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Old November 27th, 2007, 16:55   #13
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I got my replacement flange a bit ago but haven't taken the time to install it yet. The cold is making the leak worse so I guess it's getting done this weekend.
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Old December 27th, 2007, 15:00   #14
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Default Bad Coolant Flange - GOOD OEM vs BAD

My coolant flange was damaged during my tranny swap, and so I bought another one for $6.20. Well $41 of G12 coolant later, I found out the new one is defective.

So I am posting these pics so maybe someone else can avoid my this by just looking at the part. I bought the part online, and it looks just like the OEM except for the little circles in the sealing groove. I would not be surprised if some of these also made there way to the dealers.



EDIT: You might notice some glue which is painted filler epoxy which I used to glue the OEM back together and reinforce the new part (before I new about the defect).
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Old January 14th, 2008, 04:52   #15
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cattleman...

What is the part number of "#10"? I need to order one up...
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