Operation CHARM: Car repair manuals for everyone.

Cooling System Components, Removing and Installing



Cooling system components, removing and installing

Notes:
^ When the engine is warm the cooling system is under pressure. If necessary release pressure before starting repairs.
^ Hoses are secured with spring clips. During repairs, only use spring clips.
^ VAG 1921 phers are recommended to install spring clips.
^ When installing coolant hoses; route stress-free, so they do not come into contact with other components. Observe markings on coolant connections and hoses.

- Check cooling system for leakage using VAG 1274 cooling system tester and 1274/9 adaptor.
Cooling system components (body side) => Refer to Cooling system components (body side), removing and installing.
Cooling system components (engine side) => Refer to Cooling system components (engine side), removing and installing.
Coolant hoses, connection diagram => Refer to Coolant hose connection diagram.
Engine coolant, draining and filling => Refer to Cooling system, draining and filling.
Coolant mixture ratios.






Cooling system components (body side), removing and installing
1- Radiator
^ Removing and installing
- If replaced, also replace entire engine coolant
2- O-ring
- Replace
3- Coolant hose, upper
^ Attached to radiator with retaining clip
^ Coolant hoses, connection diagram => Refer to Coolant hose connection diagram.
4- 4 Nm (35 inch lbs.)
5- Cap
- Check using: VAG 1274 cooling system tester and VAG 1274/9 adaptor
^ Test pressure: 1.4 to 1.6 bar
6- 2 Nm (18 inch lbs.)
7- Expansion tank
- Carry out leak test of cooling system with VAG 1274 cooling system tester and VAG 1274/8 adaptor
8- Connector
9- to coolant hose
^ Coolant hoses, connection diagram
10- Air ducting
11- 10 Nm (7 ft. lbs.)
12- Additional fan
^ optional equipment
13- Fan ring
^ for auxiliary fan
14- Retaining clip
- Ensure it is seated securely
15- Fan ring
16- Radiator fan
17- Bracket
^ for radiator fan connector
18- Coolant hose, lower
^ Attached to radiator with retaining clip
^ Coolant hoses, connection diagram
19- Thermo switch F18
^ 35 Nm (26 ft. lbs.)
^ 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
20- Bracket
^ for radiator, lower
21- Bracket
^ for radiator, upper
- Note installation position






Cooling system components (engine side), removing and installing
1- Heat exchanger for occupant heating system
2- 4-pin harness connector
^ Wiring cavities 1 and 3 for G62
^ Terminals 1 and 3: gold plated
3- Engine Coolant
^ Temperature sensor G62
^ for Engine Control Module
^ with Engine Coolant Temperature gauge sensor G2 If necessary, release cooling system pressure before removing
^ Checking:
4- 2-pin harness connector for vehicles with A/C only
5- A/C cut-out Thermal switch F163 Vehicles with A/C only. otherwise a blind plug
6- Coolant pipe
^ Coolant hoses, connection diagram
7- Retaining clip
- Ensure it is securely seated
8- 10 Nm (7 ft. lbs.)
9- to expansion tank
^ Coolant hoses, connection diagram
10- to top of radiator
^ Coolant hoses, connection diagram
11- O-ring
- Replace
12- Connection
13- to bottom of radiator
^ Coolant hoses, connection diagram
14- oil cooler
^ Removing and installing:
=> Refer to Lubrication system components, removing and installing (item 17).
15- Engine Coolant thermostat
^ Checking: heat-up thermostat in water
^ Opening starts @ approx. 86°C
^ Opening lift: 7 mm minimum
^ Removing and installing => Refer to Ribbed belt, removing and installing.
16- Toothed belt
- Mark engine direction of rotation before removing
- Check for wear
- Do not kink Removing, installing and tensioning
=> Refer to Toothed belt, removing, installing and tensioning.
17- Coolant pump
- Check arm for ease of movement
- If damaged and leaking replace complete assembly
^ Removing and installing
18- 15 Nm (11 ft. lbs.)
19- Toothed belt guard, rear
20- 20 Nm (15 ft. lbs.)
21- Throttle Control Module
^ Heated by engine coolant
22- to expansion tank, upper
^ Coolant hoses, connection diagram
23- O-ring
- Replace if damaged