Page 113 of 136
Downloaded from www.Manualslib.com manuals search engine Cooling System19
Edition 11.96
Removing and installing radiator
Notes:
Always replace seals and gaskets.
Lifting vehicle with lift platform page 10-1,
Removing and installing engine.
Special tools, testers and aids required Torque wrench 5...50 Nm (e.g. V.A.G 1331)
Wire
Removing
- Drain coolant page 19-3.
- Unplug connector of thermostatic switch
(F18) -1- and separate plug connections -2- and -3- at the fan shroud (press locking cat- ches).
- Detach coolant hoses at connection fitting of the radiator (pull off retaining clip).
Models with air conditioning
- Unscrew the 4 bolts -arrows- attaching the
condenser.
Important!
The refrigerant circuit of the air conditioning sys-tem must not be opened.
Note: In order to avoid damage to the condenser andalso to the refrigerant pipes/hoses, ensure that
the pipes and hoses are not over-tensioned,kinked or bent.
Page 114 of 136
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19Cooling System
Edition 11.96
- Detach bracket -arrow- for refrigerant pipe. Continued for all models
- Remove both headlights: ⇒ Electrical System; Repair Group 94; Re- moving and installing headlights
- Remove the 4 bolts -arrows- for attaching
the top radiator mount.
- Remove the 4 bolts -arrows- for attaching
the bottom radiator mount.
Page 115 of 136
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Edition 11.96
Models with air conditioning
- Pull out radiator slightly together with conden-
ser.
- Detach clip -arrow- for attaching refrigerant
pipe.
Continued for all models
- Remove fan shroud (4 bolts).
Note: When removing and installing the fan shroud,ensure that the radiator ribs are not damaged.
- Carefully take out the radiator downward. Installing Installation is performed in the reverse order; pay attention to the following points:
- Tighten thermostatic switch -1- to
35 Nm.
- Fit on the brackets -2- and -3- at the radiator, as illustrated.
- Tighten the bolts for attaching the fan shroud and radiator mounts to
10 Nm.
- On models with air conditioning, tighten the bolts for attaching condenser and bracketsfor refrigerant pipes to10 Nm.
- Replace O-rings in the connection fittings of the coolant hoses.
- Insert drain plug for coolant.
- Fill system with coolant ⇒ page 19-3.
- Install headlights: ⇒ Electrical System; Repair Group 94; Re- moving and installing headlights
- Electrical connections and routing: ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Page 116 of 136
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Page 117 of 136
Downloaded from www.Manualslib.com manuals search engine Fuel Supply System20
Edition 11.96
Removing and installing parts of the fuel supply system
Notes:
Hose connections are secured with screw-
type, spring strap or clamp-type clips.
Always replace clamp-type clips by spring
strap clips or screw-type clips.
Fuel hoses at the engine must be securedonly with spring strap clips. It is not permitted
to use clamp-type or screw-type clips.
Always replace seals and gaskets when
carrying out removal and installation work.
Pay attention to safety precautions page 20-4.
Pay attention to rules for cleanliness page 20-4.
Removing and installing parts of the activatedcharcoal filter system page 20-12.
Servicing throttle mechanism page 20-12.
Setting throttle cable page 20-13.
Page 118 of 136
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20Fuel Supply System
Edition 08.96
Removing and installing fuel tank with attached parts and fuel filter
1 - Overflow hose
2 - O-ring
Replace
3 - Gravity valve To remove, unclip valve and lift up and out of filler neck
Inspect valve for blockage valve vertical: open valve tilted 45°: closed. 4 - Vent pipe
To activated charcoal filter page 20-12, item 5
5 - Cap Replace seal if damaged
6 - Tensioning ring
7 - Rubber bowl
Page 119 of 136
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Page 120 of 136
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20Fuel Supply System
Edition 08.96
Safety precautions when carrying out work on fuel supply system
Important!
Fuel system is pressurised! Place cleaning ragsaround the connection point before opening the
system. Then, release pressure by carefullyloosening the connection point.
Pay attention to the following points when re- moving and installing the fuel gauge sender or the fuel pump (fuel delivery unit) from the fuel tank: Fuel tank should be not more than
2/3 full.
The extraction hose of an exhaust extraction system should be placed close to the assembly opening of the fuel tank and the extraction system switched on before commencing work in order to extract the fuel vapours which are released. If no exhaust extraction system is available, it is possible to use a radial fan with a delivery volume of more than 15 m
3/h (motor not
positioned in the air flow).
Avoid skin contact with fuel! Wear fuel- resistant gloves!
Rules for cleanliness
Pay careful attention to the following „5 rules“for cleanliness when carrying out work on the fuel supply/fuel injection system: Thoroughly clean connection points and the surrounding area before disconnecting.
Place removed parts down on a clean
surface and cover over. Do not use fluffing cloths!
Carefully cover over or seal opened com- ponents if repairs are not carried out imme-
diately.
Install only clean parts: Do not remove replacement parts from their wrapping until just before installing. Do not use parts which have been stored unwrapped (e.g. in tool boxes etc.).
If the system is open:
Avoid working with compressed air, if possible.
Avoid moving the vehicle, if possible.
