Cooling System Components Removing and Installing
Cooling system components, removing and installing
WARNING!
When doing any repair work, especially in the engine compartment, due to the cramped conditions, pay attention to the following:
^ Route all sorts of pipes (e.g. or fuel, hydraulics, evaporative emissions system, coolant, refrigerant, brake fluid and vacuum pipes and hoses) and electrical wiring so that the original positions are restored.
^ Make sure sufficient clearance to all moving or hot components
Notes:
^ When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work.
^ Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.
^ Assembly tool VAS 5024 or hose clip pliers V.A.G 1921 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 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.
Cooling system components (body side)
1-Radiator Radiator
^ Removing and installing.
^ After replacing replace entire coolant Draining and Filling
2-O ring
^ Replace if damaged
3-Upper coolant hose
^ Secured to radiator with retaining clip
^ Check securely seated
^ Coolant hose connection diagram.
4-Air ducting
5-10 Nm
6-Additional fan
^ Only vehicles with optional equipment
7-Fan ring
8-Retaining clip
^ Check seated securely
9-Connector
10-Radiator fan
11-Bracket For radiator fan connector
12-Lower coolant hose
^ Secured to radiator with retaining clip
^ Check securely seated
^ Coolant hose connection diagram.
13-O ring
^ Replace
14-Thermoswitch (F18), 35 Nm
^ For electric fan
^ Switching temperatures:
Stage 1 on: 92 to 97°C off: 84 to 91°C
Stage 2 on: 99 to 105°C off: 91 to 98°C
15-Bracket
^ For radiator
^ Note installed position
16-15 Nm
Cooling system components (engine side)
1-15 Nm
2-Toothed belt Timing Components
^ Mark D.O.R. before removing
^ Check for wear
^ Do not kink
^ Removing, installing and tensioning. Timing Components
3-Coolant pump Water Pump
^ Check for ease of movement
^ If damaged or leaking replace complete
^ Removing and installing.
4-O ring
^ Replace
5-Coolant thermostatThermostat
^ Checking: heat-up thermostat in water
^ Opening commences approx. 87°C
^ Ends approx. 102°C
^ Opening lift min. 7 mm
6-O ring
^ Replace
7-Connection
8-To heat exchanger
^ Coolant hose connection diagram.
9-O ring
^ Replace
10-Connector
^ 4 pin
11-Coolant
^ temperature sender (G62)
^ With coolant temperature gauge sender (G2)
^ For engine control module
^ If necessary release pressure in cooling system before removing
12-Retaining clip
^ Check seated securely
13-Upper coolant hose
^ Secured to radiator with retaining clip
^ Check securely seated
^ Coolant hose connection diagram.
14-Lower coolant hose
^ Secured to radiator with retaining clip
^ Check securely seated
^ Coolant hose connection diagram.
15-Oil cooler
^ Removing and installing.
16 From heat
^ exchanger
^ Coolant hose connection diagram.
17-Lower coolant pipe
^ Coolant hose connection diagram.
18-10 Nm
19-Cap
^ Check with cooling system tester V.A.G 1274 and adapter V.A.G 1274/9
^ Test pressure 1.4 to 1.6 bar
20-Seal
^ Replace damaged
21 10 Nm
22-Expansion tank
^ Carry out leak test of cooling system with cooling system tester V.A.G 1274 and adapter V.A.G1274/8
23 To turbocharger
^ Coolant hose connection diagram.
24-15 Nm
25-To upper coolant hose
^ Only engine code AWP with automatic transmission
^ Coolant hose connection diagram.
26-After-run coolant pump (V51)
^ Only engine code AWP with automatic transmission
^ Coolant hose connection diagram.
^ Checking
27 From-turbocharger
^ Only engine code AWP with automatic transmission
^ Coolant hose connection diagram.
Coolant hose connection diagram
Only vehicles with engine code AWD
Vehicles with engine code AWP (manual transmission), AWW (manual and automatic transmission).
Vehicles with engine code AWP (automatic transmission).
1-Radiator Radiator
2-Oil cooler
3-Coolant thermostat housing Thermostat
4 Cylinder-head/cylinder block Engine
5-Expansion tank
6-Turbocharger Powertrain Management
7-Heating system heat exchanger
8-Connection
9 Transmission Transmission and Drivetrain
^ oil cooler
^ Only with automatic transmission
10-Lower coolant pipe
11-Intake manifold Engine
12-Drain plug
Vehicles with engine code AWP (manual transmission), AWW (manual and automatic transmission)
1-Expansion tank
2-Turbocharger
3-Intake manifold
4 Cylinder
^ head/cylinder block
5-Connection
6-Heating system heat exchanger
7-Lower coolant pipe
8 Transmission-oil cooler
^ Only engine code AWW with automatic transmission
9-Upper coolant hose
10-Drain plug
11-Radiator
12-Lower coolant hose
13-Oil cooler
14 Coolant
^ thermostat housing
15-Coolant pump
16-Coolant pipe
Vehicles with engine code AWP (automatic transmission)
1-Expansion tank
2-Turbocharger
3-Intake manifold
4 Cylinder
^ head/cylinder block
5-Coolant pipe
6-Connection
7-Heating system heat exchanger
8 Transmission-oil cooler
^ Only with automatic transmission
9-Lower coolant pipe
10-Oil cooler
11-Upper coolant hose
12-Radiator
13-Lower coolant hose
14-Afterrun coolant pump (V51)
15 Coolant-thermostat housing
16-Coolant pump