Cooling system components, removing and installing

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Cooling system components, removing and installing

Warning!

Hot steam may escape when opening expansion tank.

Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a rag and open carefully.

Caution!

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all the various lines (e.g. for fuel,

hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.

Ensure sufficient clearance to all moving or hot components.

Note:

Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.

The spring-type clip pliers VAS 5024 A are recommended for installing spring-type clips.

When installing coolant hoses route stress-free, so that they do not come into contact with other components (observe markings on coolant

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connection and hose).

Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapters V.A.G 1274/8 and V.A.G 1274/9 .

Radiator, assembly overview 19-1, Radiator, assembly overview .

Coolant fan, assembly overview 19-1, Coolant fan, assembly overview .

Cooling system components (on body) - assembly

overview 19-1, Cooling system components (Body side), assembly overview .

Cooling system components (on engine) - assembly overview 19-1, Cooling system components (engine side), assembly overview .

Coolant hose connection diagram 19-1, Coolant hose connection diagram .

Draining and filling with coolant 19-1, Cooling system, draining and filling .

Coolant mixture ratios 19-1, Cooling system, draining and filling

Coolant pump, removing and installing 19-1, Coolant pump, removing and installing .

Cooling system, checking for proper seal 19-1, Cooling system, checking for proper seal

Radiator, assembly overview

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Upper coolant hose

Secured to radiator with a retaining clip

Ensure seated tightly

Radiator

Removing and installing 19-1, Radiator, removing and installing

If the radiator was replaced, the coolant must be

replaced.

Condenser

Oil cooler

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For transmission oil

Oil cooler

For power steering

Lock carrier

10 Nm

Low-temperature cooler

For generator and fuel cooling

Only with certain equipment options

10 Nm

Rubber bushing

For lock carrier

Retaining clip

Check for secure seat

Rubber bushing

For bottom of radiator

Lower coolant hose

Secured to radiator with a retaining clip

Coolant hose

Secured to top of radiator

To reservoir

Coolant fan, assembly overview

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Coolant Fan V7

Fan support

10 Nm

Coolant Fan 2 V177

Coolant Fan Control (FC) Control Module J293

10 Nm

Cooling system components (Body side), assembly overview

Caution!

When doing any repair work, especially in the engine compartment, pay attention to the following due to

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clearance issues:

Especially concerning the coolant hoses Item - 2 - and Item - 3 - , ensure that there is

sufficient clearance between them and to all moving or hot components, to prevent damages.

After-run coolant pump V51

Location of pump 19-1, Location of

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Coolant hose

To After-Run Coolant Pump V51

Coolant hose

From cylinder head

From radiator

Reservoir

Perform cooling system leakage test with cooling system tester V.A.G 1274 and adapter V.A.G 1274/8

Depending on optional equipment, connection may be sealed with a blanking plug.

Sealing cap

Check using cooling system tester V.A.G 1274 and adapter V.A.G 1274/9

Test pressure 1.4 to 1.6 bar

Coolant hose

From heat exchanger for heater unit

Coolant hose

From After-Run Coolant Pump V51

To heat exchanger for heater

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unit

From heat exchanger for heater unit

To thermostat housing

Location of After-Run Coolant Pump V51

The After-Run Coolant Pump V51 - 2 - is secured with damper rings to a bracket behind the cylinder head below the Evaporative Emission (EVAP) Canister Purge

Regulator Valve N80 .

Coolant thermostat housing, assembly overview

Caution!

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Ensure sufficient clearance to all moving or hot components.

Note:

Routing of coolant hoses to thermostat housing 19-1, Cooling system components (engine side), assembly overview

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O-ring

Replace

Retaining clip

Check for secure seat

Coolant thermostat housing

8 Nm

Coolant thermostat

Note installation position

Check Vehicle Diagnosis, Testing and Information System VAS 5051 ; "Guided Fault Finding"

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Opening begins approx. 80 C

Ends approx. 105 C

Connection

Oil seal

Replace

Engine Coolant Temperature (ECT) Sensor G62

For Engine Control Module

With Engine Coolant

Temperature (ECT) Gauge Sensor G2

If necessary release

pressure in cooling system before removing

Plug

If necessary release

pressure in cooling system before removing

Cooling system components (engine side), assembly overview

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Coolant line

Between thermostat housing and lower coolant hose

Attached to cylinder block

To remove, exhaust manifold must first be removed 26- 1, Exhaust manifolds and exhaust pipes with primary catalytic converters,

removing and installing

To reservoir

To cylinder block

Connection for oil cooler

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Item - 4 -

Coolant line

Between coolant pump and thermostat housing

Secured to radiator with a quick coupling

Coolant hose connection diagram 19-1, Coolant hose connection diagram

Sealing plug, 3 Nm

O-ring

Replace

From coolant pump

20 Nm

To loosen and tighten pulley counter-hold with punch through holes

Pulley

For coolant pump

Removing and installing 19-1, Coolant pump, removing and installing

8 Nm

Coolant pump

Check for ease of movement

Removing and installing 19-1, Coolant pump, removing and installing

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From lower radiator

Coolant hose connection diagram 19-1, Coolant hose connection diagram

8 Nm

Coolant hose connection diagram

Radiator

Oil cooler

For transmission oil

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Cylinder head

Reservoir

Heater unit heat exchanger

After-Run Coolant Pump V51

Oil cooler

For engine oil

Coolant line

Cylinder block

Coolant pump

Cooling system, draining and filling

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Special tools, testers and auxiliary items required

Refractometer T10007

Drip tray V.A.G 1306

Torque wrench (5 to 50 Nm) V.A.G 1331

Spring-type clip pliers VAS 5024 A

Adapter V.A.G 1274/8

Cooling system charge unit VAS 6096

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Drain coolant

Warning!

Hot steam may escape when opening expansion tank.

Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a rag and open carefully.

- Open cap on coolant expansion tank.

- Remove noise insulation.

Repair Manual, Body Exterior, Repair Group 50, Noise insulation

- Pull coolant hose retaining clip - arrow - off downward and remove coolant hose from radiator.

Note:

Observe disposal regulations for coolant!

- In addition, to drain the coolant from the engine, disconnect the coolant hose at the oil cooler - arrow - . Fill with coolant

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Note:

Only use coolant additive G 12 plus according to

"TL-VW 774 F" . Distinguishing feature: colored violet

"G 12" and coolant additives marked "according to TL-VW 774 F" prevent frost and corrosion damage, scaling and also raise the boiling point of the

coolant. For this reason the system must be filled all year round with frost and corrosion protection

additives.

Because of its high boiling point, the coolant improves engine reliability under heavy loads, particularly in countries with tropical climates.

Protection against frost must be assured to about - 25 C (in arctic climatic countries to about -35 C).

The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The anti-freeze ratio must be at least 40 %.

If for climatic reasons a greater frost protection is required, the amount of G 12 plus can be increased, but only up to 60 % (frost protection to about -40 C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced.

If the radiator, heater core, coolant pump or cylinder head gasket was replaced, completely replace engine coolant.

Refractometer T10007 is recommended for determining frost protection density.

Recommended mixture ratios:

Frost protection to Anti-freeze portion G 12 ¹⁾ Water ¹⁾

-13 F (25 C) 40% 4.0 l 5.0 l

-31 F (35 C) 50% 4.5 L 4.5 L

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1) The quantity of coolant can vary depending upon the vehicle equipment.

Work procedure

- Install coolant hoses and secure.

- Screw adapter V.A.G 1274/8 onto expansion tank.

- Fill coolant circuit using cooling system charge unit VAS 6096 : Operating instructions for cooling system charge unit VAS 6096

Radiator, removing and installing

Special tools, testers and auxiliary items required

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Torque wrench V.A.G 1331

Removing

- Drain coolant 19-1, Cooling system, draining and filling .

- Pull retaining clips out of quick-release couplings for upper and lower coolant hoses and pull coolant hoses off radiator.

- Remove front bumper:

Repair Manual, Body Exterior, Repair Group 63, Assembly overview - front bumper

- Bring lock carrier into service position:

Repair Manual, Body Exterior, Repair Group 50, Body - front; Lock carrier, service position

- Remove coolant fan and fan support 19-1, Coolant fan, assembly overview .

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- Loosen securing clips for condenser and transmission oil cooler.

- Remove upper radiator securing bolts and remove radiator upward.

Installing

Installation is performed in the reverse order of removal, noting the following:

- Fill with coolant 19-1, Cooling system, draining and filling .

- Electrical connections and routing: Electrical Wiring Diagrams, Troubleshooting and Component Locations binder

- Install front bumper

Repair Manual, Body Exterior, Repair Group 63, Assembly overview - front bumper

- Check headlight adjustment and adjust if necessary:

Repair Manual, Maintenance

Coolant pump, removing and installing

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Special tools, testers and auxiliary items required

Torque wrench (5 to 50 Nm) V.A.G 1331

Water pump wrench V.A.G 1590

Removing

- Drain coolant 19-1, Cooling system, draining and filling .

- Remove ribbed belt 13-1, Ribbed belt, removing and installing .

Note:

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To remove the coolant pump, the pulley need not be removed.

- Remove coolant pump bolts through holes in belt pulley - arrows - and remove coolant pump.

If coolant pump must be replaced:

- Remove belt pulley. Hold belt pulley with water pump wrench V.A.G 1590 when doing this.

Installing

Installation is performed in the reverse sequence, when doing this note the following:

- Moisten new O-ring with coolant.

- Install coolant pump.

- Tighten securing bolts. Torque specification: 8 Nm - Install ribbed belt 13-1, Ribbed belt, removing and installing .

- Fill with coolant 19-1, Cooling system, draining and filling .

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Cooling system, checking for proper seal Special tools, testers and auxiliary items required

Cooling system tester V.A.G 1274

- Screw the cooling system tester V.A.G 1274 with the adapter V.A.G 1274/8 onto the reservoir as shown.

- Operate the pump and produce a pressure of 1.4 to 1.6

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bar.

- Inspect the cooling system for leaks.

- Also test the cap:

- To do this, install the adapter V.A.G 1274/9 onto the cooling system tester V.A.G 1274 .

- Operate the pump and produce a pressure of 1.4 to 1.6 bar.

- The pressure relief valve must not open before 1.4 bar.

- If the valve in the cap opens prematurely, replace the cap.