Cooling system components, removing and installing

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1 Volkswagen Touareg Cooling system components, removing and installing Page 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

2 Page 2 / 24 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. Coolant fan, assembly overview assembly overview. 19-1, Radiator, assembly 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. 19-1, Coolant hose 19-1, Cooling system, Coolant mixture ratios and filling 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 19-1, Coolant 19-1, Cooling Radiator, assembly overview

3 Page 3 / 24 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

4 Page 4 / 24 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 Ensure seated tightly Coolant hose Secured to top of radiator Ensure seated tightly To reservoir Coolant fan, assembly overview

5 Page 5 / 24 Coolant Fan V7 Fan support 10 Nm 10 Nm Coolant Fan 2 V177 Coolant Fan Control (FC) Control Module J 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

6 Page 6 / 24 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 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

7 Page 7 / 24 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

8 Page 8 / 24 unit From heat exchanger for heater unit To thermostat housing Location of After-Run Coolant Pump V51 The After-Run Coolant Pump V 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

9 Page 9 / 24 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"

10 Page 10 / 24 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

11 Page 11 / 24 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 Coolant thermostat housing To cylinder block Connection for oil cooler

12 Page 12 / 24 Item 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

13 Page 13 / 24 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

14 Page 14 / 24 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

15 Page 15 / 24 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

16 Page 16 / 24 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

17 Page 17 / 24 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

18 Page 18 / 24 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

19 Page 19 / 24 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.

20 Page 20 / 24 - 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

21 Page 21 / 24 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 19-1, Cooling system, draining and filling. - Remove ribbed belt 13-1, Ribbed belt, removing and installing. Note:

22 Page 22 / 24 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.

23 Page 23 / 24 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

24 Page 24 / 24 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 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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