Get Cooling Guide for Volkswagen Touareg SUV First Generation (2002-2010)

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

19 – Cooling

1

Removing and installing parts of cool‐

ing system

Caution

When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐

tions:

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

vated charcoal filter system, coolant, refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

sitions.

♦ To avoid damage to lines, ensure sufficient clearance to

all moving or hot components.

Note

♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair

work.

♦ Hoses are secured with spring-type clips. In case of repair,

only use spring-type clips.

lk

♦ Spring-type clip pliers -VAS 6340- are recommended for in‐

stallation of 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).

Test for leaks in cooling system using cooling system tester -

V.A.G 1274- and adapter for cooling system tester -V.A.G 1274/8-

and adapter for cooling system tester -V.A.G 1274/9- .

Assembly overview - radiator ⇒ page 78

Assembly overview - radiator fan ⇒ page 79 .

Removing and installing fan support with fan ⇒ page 79 .

Assembly overview - parts of cooling system, engine side, front

⇒ page 81 .

Assembly overview - parts of cooling system, engine side, rear

⇒ page 81 .

Assembly overview - parts of cooling system, body side

⇒ page 83 .

Draining and filling with coolant ⇒ page 86 .

Coolant hose schematic diagram ⇒ page 84

Coolant mixture ratios ⇒ page 86 , draining and filling with cool‐

ant.

Removing and installing coolant pump and thermostat

⇒ page 89 .

1. Removing and installing parts of cooling system

77

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.1

Assembly overview - radiator

1 - Coolant pipe

❑ Secured to fan support

lk

with spacers.

2 - To expansion tank

3 - Coolant hose

❑ Secured to top of front

end with retaining clips.

4 - Upper coolant hose

❑ Secured to radiator with

quick-release coupling.

❑ Check for secure seat‐

ing.

❑ With junction for coolant

hose leading to expan‐

sion tank.

5 - Radiator/cooler

❑ Removing and installing

⇒ page 88

❑ After renewing, renew

entire coolant.

6 - Condenser

7 - Oil cooler

❑ For gear oil

8 - Oil cooler

❑ For power-assisted

steering

9 - Lock carrier

10 - 10 Nm

11 - Low-temperature cooler

❑ For fuel cooling

❑ Only with certain equipment

12 - 10 Nm

13 - Rubber bush

❑ For lock carrier

14 - Retaining clip

❑ Check for secure seating.

15 - Rubber bush

16 - Lower coolant hose

❑ Secured to radiator with quick-release coupling.

❑ Check for secure seating.

17 - To coolant pump -V36-

18 - Coolant outlet temperature sender -G83-

19 - To coolant pump.

20 - To coolant pipe on top/side.

❑ Bolted to cylinder head bank 1.

78

Rep. gr.19 - Cooling

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.2

Assembly overview - radiator fan

1 - Radiator fan -V7-

2 - Fan support

❑ Clipped onto radiator.

❑ Check for secure seat‐

ing.

3 - 10 Nm

4 - 10 Nm

lk

5 - Radiator fan 2 -V177-

6 - Radiator fan control unit -

J293-

7 - 10 Nm

1.3

Removing and installing fan support

with fan

Special tools and workshop equipment required

♦ Spring-type clip pliers -VAS 5024A-

Removing

WARNING

Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and

scalding. Cover cap with cloth and open carefully.

– Open and close cap on coolant expansion tank.

– Release coolant hose retaining clips from front end using a

screwdriver.

1. Removing and installing parts of cooling system

79

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Unscrew coolant pipe from fan support -arrow-.

lk

– Loosen spring-type clips on coolant pipe and swivel it upwards

together with spacers.

– Disconnect connectors from radiator, loosen cable clamps on

fan support and lay wiring harness to side.

– Pull retaining ring -1- of rubber mounting on left and right in

direction of arrow off brake vacuum pump -V192- and lay

pump to side.

– Then release locking mechanisms on left and right of radiator

using a screwdriver -arrows- and lift out complete fan support

upwards.

80

Rep. gr.19 - Cooling

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

lk

1.4

Assembly overview - parts of cooling system, engine side, front

1 - Thermostat housing

2 - Coolant pump

❑ Check for ease of move‐

ment.

❑ Removing and installing

⇒ page 89

3 - Upper coolant hose

4 - To radiator

5 - Lower coolant hose

6 - Radiator outlet coolant tem‐

perature sender -G83-

❑ Before removing, re‐

lease pressure in cool‐

ing system if necessary.

7 - Retaining clip

❑ Check for secure seat‐

ing.

8 - O-ring

❑ Renew if damaged.

9 - To bottom of radiator

10 - Connection

❑ Secured to radiator with

quick-release coupling.

❑ Check for secure seat‐

ing.

11 - Coolant pump -V36-

❑ Checking ⇒ page 85 .

❑ Fitting location of pump:

bolted to longitudinal

member on right.

12 - Bracket

13 - 23 Nm

14 - Non-return valve

❑ Note installation position.

❑ Arrow points towards engine.

15 - Coolant hose

16 - Coolant pipe

17 - Coolant pipe

18 - Coolant pipe, on side

19 - 10 Nm

1.5

Assembly overview - parts of cooling

system, engine side, rear

Assembly overview

1. Removing and installing parts of cooling system

81

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1 - Coolant pipe

❑ Between left and right

cylinder head

❑ With junction to heat ex‐

changer for heating, ex‐

pansion tank and upper

coolant hose.

2 - O-ring

❑ Renew.

3 - Coolant temperature send‐

er -G62-

❑ With coolant tempera‐

ture display sender -

G2- .

❑ For engine control unit.

❑ Before removing, re‐

lease pressure in cool‐

ing system if necessary.

4 - Coolant pipe

5 - To thermostat.

6 - 20 Nm

lk

7 - Gasket

8 - Coolant pipe

❑ From cylinder head

bank 1

9 - Coolant pipe

❑ To oil filter housing

10 - To expansion tank

11 - To expansion tank

12 - Coolant pipe

13 - 10 Nm

14 - To upper coolant hose

15 - 10 Nm

16 - Coolant pipe, on side

❑ On cylinder head bank 1

17 - Coolant hose

18 - From heat exchanger for heater unit

19 - To heat exchanger for heater unit.

20 - Coolant pipe

21 - 10 Nm

22 - Retaining clip

❑ Check for secure seating.

23 - Connection

❑ To expansion tank

24 - 10 Nm

82

Rep. gr.19 - Cooling

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.6

Assembly overview - parts of cooling system, body side

1 - Expansion tank

❑ Test cooling system for

leaks using cooling sys‐

tem tester -V.A.G 1274-

and adapter for cooling

system tester -V.A.G

1274/8- .

2 - Cap

❑ Check using cooling

system tester -V.A.G

1274- and adapter for

cooling system tester -

V.A.G 1274/9- .

❑ Test pressure: 1.4…1.6

bar.

3 - Connector

❑ For coolant shortage in‐

dicator

4 - Spring-type clip

❑ Check for secure seat‐

ing.

lk

5 - Coolant hose

6 - To connection

7 - To coolant pipe

8 - Overflow hose

9 - 10 Nm

10 - Coolant pipe

11 - To upper coolant hose

12 - 8 Nm

1. Removing and installing parts of cooling system

83

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.7

Coolant hose schematic diagram

1 - Radiator/cooler

2 - Upper coolant hose

3 - Lower coolant hose

4 - Coolant pump -V36-

5 - Non-return valve

❑ Note installation posi‐

tion.

❑ Arrow points in direction

of flow.

lk

6 - Coolant pipe

❑ Secured to cylinder

head bank 1.

7 - Alternator

8 - Oil cooler

❑ For engine oil.

9 - Expansion tank

10 - Heat exchanger for heater

unit

11 - Coolant pipe

❑ Secured between cylin‐

der head bank 1 and cyl‐

inder head bank 2.

12 - Coolant temperature

sender -G62-

13 - Cylinder bank 2.

14 - Cylinder bank 1.

15 - Coolant pipe

❑ Connected to cylinder

head bank 1.

16 - Coolant pipe

❑ To thermostat housing

17 - Coolant pump

18 - Thermostat housing

Fitting location of water pump -V36-

The water pump -V36- -2- is clipped to the bracket with damping

rings and is bolted to the longitudinal member on right together

with the bracket.

84

Rep. gr.19 - Cooling

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

1.8

Checking water pump -V36-

Special tools and workshop equipment required

♦ Voltage tester -V.A.G 1527/B-

♦ Auxiliary measuring set -V.A.G 1594/C-

lk

♦ Current flow diagram

Test prerequisite

•

Fuse -16- -arrow- must be OK.

Test procedure

– Pull 2-pin connector -1- off coolant pump -V36- -2-.

1. Removing and installing parts of cooling system

85

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Connect contact -1- of water pump -V36- to battery positive

lk

(+) and contact -2- to earth (-) using auxiliary cables from aux‐

iliary measuring set -V.A.G 1594C- . Pump must run.

If the pump does not start operating:

– Renew water pump -V36- .

1.9

Draining and filling coolant

Special tools and workshop

equipment required

♦ Refractometer -T10007-

♦ Drip tray -V.A.G 1306-

♦ Spring-type clip pliers -VAS

5024A-

♦ Adapter for cooling system

tester -V.A.G 1274/8-

♦ Torque wrench -V.A.G

1331-

♦ Cooling system charge unit

-VAS 6096-

86

Rep. gr.19 - Cooling

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

Draining

WARNING

Steam may escape when expansion tank is opened. Wear eye

protection and protective clothing to avoid eye injuries and

scalding. Cover cap with cloth and open carefully.

– Open cap on coolant expansion tank.

– Remove noise insulation. ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front; Assembly overview - noise insu^ll^ka‐

tion .

– Place drip tray -V.A.G 1306- under vehicle.

– Disconnect coolant hoses -1- from water pump -V36- .

Note

Follow disposal regulations for coolant!

Filling

1. Removing and installing parts of cooling system

87

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

lk

Note

♦ Use only coolant additive G12 plus in accordance with

„TL VW 774 F“. Identification: purple colour.

♦ G 12 plus and coolant additives marked „Conforming to

TL VW 774 F“ prevent frost and corrosion damage and scaling

and also raise boiling point of coolant. Therefore, the cooling

system must be filled all year round with frost and corrosion

protection additives.

♦ Because of its higher boiling point, the coolant improves en‐

gine reliability under heavy loads, particularly in countries with

tropical climates.

♦ Frost protection is required down to about -25°C (in countries

with arctic climates: down to about -35°C).

♦ The coolant concentration must not be reduced by adding wa‐

ter even in warmer seasons and in warmer countries. The

coolant additive concentration 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 are reduced again.

♦ If radiator, heat exchanger, cylinder head or cylinder head

gasket is renewed, do not reuse old coolant.

♦ The Refractometer -T10007- is recommended for determining

the current anti-freeze density.

Recommended mixture ratios:

Frost protection Anti-freeze

G 12²⁾

Water²⁾

to

quantity

4.0 l

-25 °C

-35 °C

4.0 l

4.5 l

5.0 l

4.5 l

2) The quantity of coolant can vary depending upon vehicle equipment.

– Install coolant hoses and secure.

– Screw adapter for cooling system tester -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 .

1.10

Removing and installing radiator

Special tools and workshop equipment required

♦ Drip tray -V.A.G 1306-

88

Rep. gr.19 - Cooling

lk

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

♦ Torque wrench -V.A.G 1331-

Removing

– Drain coolant ⇒ page 86 .

– Pull out retaining clips from quick-release coupling for coolant

hose at top and bottom and detach coolant hoses from radia‐

tor.

– Remove front bumper ⇒ General body repairs, exterior; Rep.

gr. 63 ; Assembly overview - front bumper

– Remove fans with fan support ⇒ page 79 .

– Loosen securing clips for condenser and ATF cooler.

– Remove upper securing bolts for radiator and remove radiator

upwards.

Installing

Installation is carried out in the reverse order. When installing,

note the following:

– Replenish coolant ⇒ page 86 .

– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.

– Install front bumper: ⇒ General body repairs, exterior; Rep.

gr. 63 ; Assembly overview - front bumper

– Check headlight adjustment and correct if necessary ⇒ Main‐

tenance ; Booklet 17.1 .

1.11

Removing and installing coolant pump

and thermostat

Special tools and workshop equipment required

♦ Drip tray -V.A.G 1306-

1. Removing and installing parts of cooling system

89

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

lk

♦ Torque wrench -V.A.G 1331-

Removing

– Drain coolant ⇒ page 86 .

– Remove upper coolant hose from thermostat housing.

– Remove radiator fans with radiator fan support ⇒ page 79 .

– Remove poly V-belt ⇒ page 18 .

– Remove toothed belt ⇒ page 34 .

If thermostat must be renewed:

– Unscrew securing bolts of thermostat housing -arrows-.

– First remove seal and then thermostat.

Installing

– Insert thermostat with bleeder valve -arrow- facing upwards.

– Moisten new O-ring with coolant and install it.

– Install thermostat housing by first screwing in all securing bolts

by hand and then tightening all bolts to specified torque of 10

Nm.

If coolant pump must be renewed:

90

Rep. gr.19 - Cooling

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– Remove toothed belt guard securing nuts -1-.

– Then unscrew all coolant pump securing bolts -arrows-.

Installation is carried out in the reverse order. When installing,

note the following:

– Insert coolant pump with gasket.

– Screw in all securing bolts by hand and tighten to specified

torque. Specified torque: 15 Nm

– Reinstall toothed belt ⇒ page 34 .

– Install poly V-belt ⇒ page 18 .

– Replenish coolant ⇒ page 86 .

1.12

Checking cooling system for leaks

Special tools and workshop equipment required

♦ Cooling system tester -V.A.G 1274-

lk

♦ Adapter for cooling system tester -V.A.G 1274/8-

♦ Adapter for cooling system tester -V.A.G 1274/9-

– Screw cooling system tester -V.A.G 1274- with adapter -V.A.G

1274/8- onto expansion tank.

– Operate pump on tester and build-up pressure of between 1.4

and 1.6 bar.

– Check cooling system tester for leaks.

– In addition, check sealing cap.

1. Removing and installing parts of cooling system

91

Touareg 2003 ➤

8-cylinder injection engine - Edition 11.2011

– To do this screw the cooling system tester -V.A.G 1274- and

the adapter for cooling system tester -V.A.G 1274/9- on seal‐

ing cap as shown.

– Operate pump on tester and create a pressure of between 1.6

bar.

– The pressure relief valve in the sealing cap must remain

closed for the time being.

– If valve opens before test is complete, renew sealing cap.

lk

92

Rep. gr.19 - Cooling

Cooling for Your Volkswagen Touareg SUV First Generation (2002-2010)

Related Topics

Popular Owner Manuals

Latest Owner Manuals