Ive own both Mk6 1.8T Jetta and now have a Mk5 2.5L Jetta and both have required new radiators at 150k miles. they have not been leaking coolant since.
Replaced radiator. Flushed out nasty brown water from cooling lines, heater core and flushed with distilled water 3 times. Pulled vacuum on cooling System and Refilled with G13 premix.
EDIT: SOLVED - noticed no leakage around thermostat, coolant ball, all belts were dry, and upper radiator dry. In the end it was the radiator.
For new parts to install, I have Autotech headers, USRT Smartshift linkage, a new Bosch O2 sensor, Autobahn Autoworx silicone coolant hoses, proper G11 coolant, and a Nissin replacement radiator.
90 16v Passat rad fit just fine in my mk1 Jetta with a single fan mk1 (which mounted to the rad just fine) you can cut the wires and set them up for how ever you like.
Valeo 3 row radiator is what i use and it works great
Regarding our 1997 Jetta GLS that we've had since it was brand-new, I was topping off the original G11 with G12+ since about 2000, without any problems. A few years ago we had the radiator replaced, and the coolant was all changed out to G12 -- that is, the current G12.
That tool is a god send! Unrelated, but burping a radiator sucks too.
The radiator on my 2016 is leaking, although leak isn't really the right word. Maybe porous. The hole is so small, it takes months to show a change in the coolant reservoir. On some days, given proper conditions, a small wisp of steam is visible coming from the radiator area. I added a UV dye to the cooling system, and it is visible then.
my valeo radiator didn't come with anything.. im just hoping it doesn't leak from that zone.
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