Typical cooling system failures

1. The engine does not reach a temperature of approx. 90 C

 faulty thermostat - the bracket cracks causing a large circulation
permanently. The engine temperature then stays at approx. 70 C. Third
party thermostats are often leaky and fail rapidly. Check if the
thermostat is good by starting the engine and letting the temperature
reach 70 C then touch the upper radiator hose near thermostat. If it is
warm the thermostat is leaky and has to be replaced. The thermostat
has to open at 85-90 degrees.
 faulty coolant temperature sensor. Check can be made by
comparing the values indicated by the temperature gauge with the
values read with VAG-COM or by starting the engine and waiting until
the radiator fan switches on (usually at approx. 95 C). If the fan
switches on at let's say 80 C, the sensor sends wrong values and needs
to be replaced. Third party sensors are generally not accurate so it's
worth buying an original sensor.
 faulty temperature gauge - very rare
Note: driving with less coolant is not indicated. If the level is too low, the
temperature sensor may not pick up correct values.

2. The engine is overheating

 faulty thermostat - jammed in the closed position or damaged
housing worn in the middle where the shaft of the thermostat butts (the
latter is quite often in 1.6 AEE engines). This failure is causing the big
cooling circuit to not open and the engine to overheat. Sometimes a
partial blockage of the thermostat is manifested by engine overheating
when driving at higher speeds (the temperature increasing significantly
with speed). In this case, you must replace the thermostat.
 water instead of coolant.
 the radiator fan not working - damaged radiator fan switch, fan
motor (rare defect), fuse. The fan not operating can have other cause
through which the heated liquid does not go to the radiator (jammed
thermostat, zapowietrzony układ, clogged radiator, damaged head
gasket)
 damaged expansion tank cap - cooling system has to work at the
appropriate pressure. A damaged cap causes a pressure escape or a
pressure too high. If the cap does not release the pressure, the coolant
begins to boil.
 clogged cooling system (most often the radiator) - the thermostat
opens properly, the radiator is cold and engine temperature is rising.
 Diagnosis is best done by removing the thermostat to exclude its
possible failure as cause. If the radiator will not heat up. it is probably
clogged. Clogging the radiator is usually accompanied by high pressure
at the opening of the thermostat temperatures and higher. A similar
symptom gives a damaged head gasket.
 damaged head gasket - This damage is usually accompanied by loss
of coolant, white smoke, a significant increase in the pressure in the
cooling system, the lack of heating the interior, bleeding system.
Damage can be confirmed or ruled out with special hardware to detect
CO2 in liquid or homemade: fire up a cold engine, let it run for about a
minute, turn it off, check the condition of rubber hoses (should be soft)
and unscrew the cap of expansion tank. If unscrewing is accompanied
by a lot of pressure, as described previously, the engine tests passed
successfully and probably the gasket head is damaged and needs
replacing.
 damaged copper gasket below liners. This causes similar
symptoms to head gasket failure. It is quite rare and repair requires
dismantlng the engine (cylinder head, pistons, liners and other things
along the way)
 faulty water pump - engine quickly reaches temperature, usually
coolant does not return to expansion tank, and there is no heating.
Coolant may be leaking from water pump and the radiator can remain
cold.
 missing plastic shroud directing air to the radiator.
3. No heat from heater
 clogged cooling system
 faulty water pump (usually when accelerating you can feel some heat)
 clogged heater or internal damage (cracks occur in the middle of
plastic case causing a lack of flow of fluid through the entire heater,
running at a higher speed results in its proper operation)
4. Incorrect readings on coolant temperature gauge

If the temperature stays too high and the fan t kicks in above its rated
temperature, the cooling system:
 has a leak
 has trapped air below temp. sensor
or there is a decalibrated
 temp. sensor
 fan thermoswitch
If the temperature stays too low, the thermostat is stuck open.
 
Possible signs of a failed head gasket
Note: some of the symptoms could be attributed to other parts failure too

1. Cooling system related

 constant overheating
 excessive pressure - constant bubbling in expansion tank, very stiff
hoses, constant coolant spill out from expansion tank
 oily residues in expansion tank
 smell of hydrocarbons in expansion tank
 outside leaks
2. Lubrication system related
 emulsion residues in oil filler cap or on oil dipstick
 oil level above normal limit
 outside leaks
 excessive pressure in crankcase, smoking
3. Exhaust system related
 white smoke out the tailpipe, sometimes specific smell
4. Combustion related
 misfire or rough idle
 lowered compression