Volkswagen Golf > VW Rabbit GTI 2006->

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1 Стр. 1 из 24 Volkswagen Golf > VW Rabbit GTI 2006-> 19-1 Cooling system components Warning! Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover sealing cap with a rag and open carefully. Note: The cooling system is under pressure when engine is warm. If necessary reduce pressure before repair. Secure all hose connections using hose clamps appropriate for the model type. Hose clamp pliers V.A.G 1921 or Spring Type Clip Pliers VAS 5024A are recommended for installing spring clamps. Replace gaskets and O-rings. The arrows which are marked on coolant lines and hoses must face each other. Cooling system components (on engine), assembly overview 19-1, Cooling system components (on engine), assembly overview Cooling system components (on body), assembly overview 19-1, Cooling system components (on body), assembly overview Coolant, draining and refilling and refilling 19-1, Coolant, draining Coolant pump, removing and installing pump, removing and installing 19-1, Coolant Removing and installing Coolant Fan V7 and Coolant Fan 2 V , Coolant Fan V7 and Coolant Fan 2 V177, removing and installing Radiator, removing and installing removing and installing Cooling system, checking for leaks 19-1, Radiator, 19-1, Cooling

2 Стр. 2 из 24 system, checking for leaks Cooling system components (on engine), assembly overview Mounting bolt Mounting bolt Coolant pipe Connection hose O-ring Replace Connection 10 Nm Retaining clip

3 Стр. 3 из 24 O-ring Replace Engine Coolant Temperature (ECT) Sensor G62 Connection hose Connecting piece Connection hose Connection hose Connection hose Coolant pipe 5 Nm Connection hose Coolant pipe 5 Nm Coolant distribution housing With thermostat Starts to open 87 C 15 Nm Coolant pump Removing and installing 19-1, Coolant pump, removing and installing 15 Nm Coolant Pump V50, assembly overview

4 Стр. 4 из 24 3 Nm Coolant pipe Spring clip Coolant line To turbocharger Coolant hose Bracket Coolant hose Toward radiator inlet Coolant Pump V50 Functioning can be checked

5 Стр. 5 из 24 via output Diagnostic Test Mode (DTM) Vehicle Diagnosis, Testing and Information System VAS Nm 5 Nm Cooling system components (on body), assembly overview Radiator Removing and installing 19-1, Radiator, removing and installing After replacing, completely replace coolant

6 Стр. 6 из 24 O-ring Replace if damaged Upper coolant hose To connection sleeve at cylinder head Cap Check using cooling system tester V.A.G 1274 and adapter V.A.G 1274/9 Pressure release valve must open at a pressure of 1.4 to 1.6 bar. Connector 5 Nm Expansion tank Perform leak test of cooling system cooling system tester V.A.G 1274 and adapter V.A.G 1274/8 Lower coolant hose To connection for coolant regulator 5 Nm 5 Nm Coolant Fan 2 V177 Removing and installing 19-1, Coolant Fan V7 and Coolant Fan 2 V177, removing and installing Coolant Fan V7 Removing and installing 19-1, Coolant Fan V7 and

7 Стр. 7 из 24 Coolant Fan 2 V177, removing and installing With Coolant Fan Control (FC) Control Module J293 Connector Intake air elbow Coolant hoses, connection diagram Expansion tank With sealing cap Pressure relief valve in cap, checking Item Turbocharger

8 Стр. 8 из 24 Removing and installing 21-1, Turbocharger, removing and installing Cylinder head/cylinder block After replacing, replace coolant Coolant connection Heater core of heater After replacing, replace coolant Bypass thermostat Starts to open 80 C Transmission oil cooler Only with automatic transmission Engine oil cooler Intake manifold Removing and installing 24-1, Intake manifold, removing and installing Radiator Removing and installing 19-1, Radiator, removing and installing After replacing, replace coolant Coolant Pump V50 Functioning can be checked via output Diagnostic Test Mode (DTM) Vehicle Diagnosis, Testing and Information System VAS

9 Стр. 9 из Coolant distribution housing With thermostat Coolant, draining and refilling Special tools, testers and auxiliary items required Adapter V.A.G 1274/8 Drip tray V.A.G 1306 Spring type clip pliers VAS 5024A

10 Стр. 10 из 24 Cooling system filler unit VAS 6096 Refractometer T10007 Drain coolant 19-1, Drain coolant. Fill with coolant 19-1, Fill with coolant Drain coolant Note: Drained coolant must be stored in a clean container for disposal or reuse. Follow disposal regulations. Warning! Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover sealing cap with a rag and open carefully. - Open cap of coolant expansion tank. - Remove noise insulation Repair Manual, Body Exterior, Repair Group 50, Front body; noise insulation. - Disengage quick acting coupling - arrow - and

11 Стр. 11 из 24 disconnect coolant hose from cooler. Fill with coolant Note: Only coolant additive G 12 plus (according to TL VW 774 F) must be used. Characteristic: purple coloring G 12 plus (according to TL VW 774 F) may be mixed with previous coolant additive G 12! "G 12" and coolant additives marked "In accordance with TL VW 774 F" prevent frost and corrosion damage, scaling and also raise the boiling point of the coolant. For these reasons, the cooling system must be filled with radiator freeze and corrosion protection fluid all year round. Especially in countries with tropical climates or when vehicle is driven under heavy load, the coolant improves the engine reliability by its increased boiling point. Freeze protection must be guaranteed to approx. -25 C (approx. -35 C in countries with an arctic climate). The coolant concentration must not be reduced by adding water, even during the warmer season. The coolant additive portion must be at least 40%. If for climatic reasons greater frost protection is required, the amount of G 12 can be increased, but only up to 60% (frost protection to about -40 C), otherwise frost protection and cooling effectiveness will be reduced. If the radiator, heater core, cylinder head or cylinder head gasket is replaced, completely replace the engine coolant. Recommended mixture ratios: Frost protection to Anti-freeze amount G 12 1) Water 1)

12 Стр. 12 из C -35 C 40% 50% 3.2 l 4.0 l 4.8 l 4.0 l 1) The quantity of coolant can vary depending upon vehicle options. - Install insulation pan Repair Manual, Body Exterior, Repair Group 50, Front body, noise insulation. Using cooling system filler unit VAS 6096 : - Screw adapter V.A.G 1274/8 on to expansion tank. - Fill coolant circuit using cooling system filling unit VAS 6096 Operating instructions for cooling system filler unit VAS Without cooling system filler unit VAS 6096 : - Slowly fill coolant up to top marking of hatched area on expansion tank. - Close expansion tank. - Start engine and maintain an engine speed of about 2000 RPM for approx. 3 minutes. - Let engine run until fan starts up. Warning! Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover sealing cap with a rag and open carefully. - Check coolant level and top off if necessary. With engine

13 Стр. 13 из 24 at operating temperature, coolant level must be at top marking, with engine cold, it must be in center of hatched area. Coolant pump, removing and installing Special tools, testers and auxiliary items required Drip tray V.A.G 1306 Spring type clip pliers VAS 5024A Coolant pump, removing Coolant pump, installing 19-1, Coolant pump, removing 19-1, Coolant pump, installing Coolant pump, removing Warning! Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover sealing cap with a rag and open carefully. - Drain engine coolant 19-1, Drain coolant.

14 Стр. 14 из 24 - Remove toothed belt 15-1, Toothed belt, removing and installing. - Remove mounting bolts for coolant pump and remove coolant pump Remove O-ring Coolant pump, installing Installation is in reverse order of removal, note the following: - Replace O-ring. - Clean or smooth sealing surface for O-ring. - Coat new O-ring with coolant. - Insert coolant pump Installation position: Sealing plug in housing points downward. - Tighten bolts of coolant pump. - Install toothed belt 15-1, Toothed belt, removing and installing.

15 Стр. 15 из 24 - Fill with coolant 19-1, Fill with coolant. Tightening torques: Component Nm Coolant pump to cylinder block 15 Center toothed belt guard to cylinder block 10 1) 1) Insert with locking fluid Coolant lines, removing and installing Special tools, testers and auxiliary items required Spring type clip pliers VAS 5024A Removing - Remove engine cover 24-1, Air filter/engine cover, removing and disassembling. - Remove pipe - A - and hose - B --arrows-.

16 Стр. 16 из 24 - Loosen bolts - arrows - and remove charge air pipe with hose downward. - Drain engine coolant 19-1, Drain coolant. - Disconnect electrical harness connectors - arrows-. - Disconnect coolant hoses from coolant pipes - arrows -.

17 Стр. 17 из 24 - Disconnect hose - A - and remove bolt - B -. Remove front coolant pipe. - Disengage connector - A - from bracket, disconnect hose - B - and remove bolts - C -. Remove rear coolant pipe. Installing Installation is performed in reverse order of removal. Coolant distribution housing with thermostat, removing and installing Removing - Remove generator Repair Manual, Electrical Equipment, Repair Group 27, Generator. - Disconnect coolant lines 19-1, Coolant lines, removing and installing.

18 Стр. 18 из 24 - Disconnect coolant hose from coolant transfer case. To do so, pull out retaining clip Remove bolts - arrows - and remove coolant distribution housing with thermostat from engine. Installing - Clean sealing surface for O-ring. - Replace O-ring and coat it with coolant. - Place coolant distribution housing on engine block and tighten bolts uniformly to 15 Nm. - Installation is in reverse order of removal. Coolant Fan V7 and Coolant Fan 2 V177, removing and installing Coolant fan, removing - Remove engine cover.

19 Стр. 19 из 24 - Remove upper mounting bolts of air intake elbow - arrows -. - Remove noise insulation Repair Manual, Body Exterior, Repair Group 50, Front body; noise insulation. - Disconnect harness connector and remove lower mounting bolts of intake air elbow - arrows -. - Remove intake air elbow downward.

20 Стр. 20 из 24 - Disconnect electrical harness connector and lay cable free. - Remove nuts - arrows - and remove fans. Fan, installing Installation is in reverse of removal, note the following: Tightening torques: Component Nm Coolant fan to intake air elbow 10 Intake air elbow to radiator 5 Radiator, removing and installing Special tools, testers and auxiliary items required Refractometer T10007

21 Стр. 21 из 24 Drip tray V.A.G 1306 Spring Type Clip Pliers VAS 5024A Cooling system filler unit VAS 6096 Adapter V.A.G 1274/8 Radiator, removing - Drain engine coolant 19-1, Coolant, draining and refilling. - Disconnect charge air hoses - arrows -. - Bring lock carrier into service position Repair Manual, Body Exterior, Repair Group 50, Body front, lock carrier service position.. - Disconnect coolant hoses from cooler. - Remove intake air elbow with coolant fans 19-1, Coolant Fan V7 and Coolant Fan 2 V177, removing and installing. Note: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.

22 Стр. 22 из 24 - Remove bolts - arrows - from radiator. - Remove radiator downward. Radiator, installing Installation is in reverse order of removal, note the following: - When installing a new radiator, old coolant must not be reused. - Fill with coolant 19-1, Fill with coolant. Tightening torques: Component Radiator mounting to lock carrier 5 Condenser to radiator 5 Intake air elbow to radiator 5 Nm Cooling system, checking for leaks

23 Стр. 23 из 24 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 Pressure relief valve in cap, checking pressure relief valve in sealing cap 19-1, Checking Engine at operating temperature. Test sequence: Warning!

24 Стр. 24 из 24 Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover sealing cap with a rag and open carefully. - Open cap of coolant expansion tank. - Position cooling system tester V.A.G 1274 with adapter V.A.G 1274/8 on expansion tank. - Generate a positive pressure of approx. 1.0 bar using hand pump of tester. If pressure drops: - Search for leaking areas and repair malfunction. Checking pressure relief valve in sealing cap - Position cooling system tester V.A.G 1274 with adapter V.A.G 1274/9 on cap. - Pump using hand pump. Pressure release valve must open at a positive pressure of 1.4 to 1.6 bar. Volkswagen Technical Site: огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi