Transcript
Volkswagen Touareg 3.2 - Cooling system components, removing and installing
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19 - 1
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
Cooling system components, removing and installing
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 overview .
19-1, Radiator, assembly
Coolant fan, assembly overview assembly overview .
19-1, Coolant fan,
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 connection diagram . Draining and filling with coolant draining and filling . Coolant mixture ratios and filling
19-1, Coolant hose 19-1, Cooling system,
19-1, Cooling system, draining
Coolant pump, removing and installing pump, removing and installing . Cooling system, checking for proper seal system, checking for proper seal Radiator, assembly overview
19-1, Coolant 19-1, Cooling
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Cooling system components, removing and installing
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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Cooling system components, removing and installing
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
Retaining clip
Check for secure seat
Rubber bushing
For lock carrier
For bottom of radiator
Lower coolant hose
Secured to radiator with a retaining clip
Ensure seated tightly
Coolant hose
Secured to top of radiator
Ensure seated tightly
To reservoir
Coolant fan, assembly overview
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Cooling system components, removing and installing
Coolant Fan V7
Fan support
10 Nm
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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Cooling system components, removing and installing
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.
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 Location of
19-1,
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Cooling system components, removing and installing
Coolant hose
Ensure seated tightly
To After-Run Coolant Pump V51
Coolant hose
Ensure seated tightly
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
Ensure seated tightly
From heat exchanger for heater unit
Coolant hose
Ensure seated tightly
From After-Run Coolant Pump V51
To heat exchanger for heater
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Cooling system components, removing and installing
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:
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:
Routing of coolant hoses to thermostat housing 19-1, Cooling system components (engine side), assembly overview
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Cooling system components, removing and installing
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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Cooling system components, removing and installing
Opening begins approx. 80 C
Ends approx. 105
Connection
Oil seal
C
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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Cooling system components, removing and installing
Coolant line
Between thermostat housing and lower coolant hose
Attached to cylinder block
To remove, exhaust manifold must first be removed 261, Exhaust manifolds and exhaust pipes with primary catalytic converters, removing and installing
To reservoir
Coolant thermostat housing
To cylinder block
Connection for oil cooler
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Cooling system components, removing and installing
Item - 4 -
Coolant line
Between coolant pump and thermostat housing
Upper coolant hose
Secured to radiator with a quick coupling
Ensure seated tightly
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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Cooling system components, removing and installing
From lower radiator
Lower coolant hose
Ensure seated tightly
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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Cooling system components, removing and installing
Cylinder head
Reservoir
Coolant thermostat housing
Heater unit heat exchanger
After-Run Coolant Pump V51
Oil cooler
For engine oil
Upper coolant hose
Coolant line
Cylinder block
Lower coolant hose
Coolant pump
Cooling system, draining and filling
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Cooling system components, removing and installing
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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Cooling system components, removing and installing
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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Cooling system components, removing and installing
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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
Cooling system components, removing and installing
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
Drip tray V.A.G 1306
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Cooling system components, removing and installing
Torque wrench V.A.G 1331
Removing - Drain coolant filling .
19-1, Cooling system, draining and
- 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 fan, assembly overview .
19-1, Coolant
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Cooling system components, removing and installing
- 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 filling .
19-1, Cooling system, draining and
- 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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Cooling system components, removing and installing
Special tools, testers and auxiliary items required
Drip tray V.A.G 1306
Torque wrench (5 to 50 Nm) V.A.G 1331
Water pump wrench V.A.G 1590
Removing - Drain coolant filling .
19-1, Cooling system, draining and
- Remove ribbed belt installing . Note:
13-1, Ribbed belt, removing and
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Cooling system components, removing and installing
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 installing . - Fill with coolant filling .
13-1, Ribbed belt, removing and 19-1, Cooling system, draining and
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Cooling system components, removing and installing
Cooling system, checking for proper seal
Special tools, testers and auxiliary items required
Cooling system tester V.A.G 1274
Adapter V.A.G 1274/8
Adapter V.A.G 1274/9
- 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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Cooling system components, removing and installing
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.
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