Page 1 of 34
19-1
Cooling system components,
removing and installing
WARNING!
Hot steam can escape from the expansion
tank when the filler cap is opened. Cover the
filler cap with a cloth and unscrew it carefully.
Notes:
When the engine is hot the cooling system is
under pressure. Carefully open filler cap on
expansion tank to release pressure before
starting repair work.
Hoses are secured with spring-type clips. When
repairing only use spring-type clips.
VAG 1921 pliers are recommended when
installing spring-type clips.
The O-rings fitted at the quick-release
connections must be replaceed if damaged or
leaking.
When installing coolant hoses, ensure that they
are free of stress and do not come into contact
with other components (observe markings on
coolant connection and hose).
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Page 2 of 34
Perform leak test on cooling system with cooling
system tester VAG 1274 and adapter VAG
1274/8.
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Page 3 of 34
19-2
Cooling system components (on body),
removing and installing
Notes:
Parts of cooling system on engine Page 19
-
8 .
Diagram of coolant hose connections Page 19
-17
.
Draining and filling with coolant Page 19
-
19
.
Coolant mixture ratios Page 19
-19
, draining
and filling cooling system.
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Page 9 of 34
19-8
Cooling system components (on engine,
front), removing and installing
1 -
Connection
For thermostat
2 -
O-ring Always replace
3 -
Thermostat Checking: heat the thermostat in waterStarts to open at about 86 COpening travel: at least 7 mm
4 -
Bolt Tightening torque: 10 Nm
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Page 10 of 34
19-9
5 -
Filler cap
Test with cooling system tester VAG 1274
and adapter VAG 1274/9 Test pressure 1.4...1.6 bar
6 -
O-ring Replace if damaged
7 -
Bolt Tightening torque: 10 Nm
8 -
Expansion tank Carry out leak test of cooling system with
cooling system tester VAG 1274 and
adapter VAG 1274/8
9 -
To rear water line Diagram of coolant hose connections
Page 19
-17
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Page 14 of 34
19-13
Cooling system components (on engine,
rear), removing and installing
1 -
To front water hose
2 -
Front coolant line
Diagram of coolant hose connections
Page 19
-17
3 -
Bleeder screw
Tightening torque: 20 Nm
4 -
Coolant hose From auxiliary water pump to front coolant
line
5 -
Auxiliary water pump
6 -
Coolant hose From rear coolant line to auxiliary water
pump
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Page 15 of 34
19-14
Repair Manual, 2.7 Liter V6 5V BiTurbo Fuel
Injection & Ignition, Engine Code(s): APB, Repair Group 01
7 -
Right coolant line From turbocharger to rear coolant line
8 -
Banjo bolt Tightening torque: 35 Nm
9 -
Coolant temperature sender (-G62-) For engine control moduleIf necessary, release pressure in cooling
system before removing Checking:
10 -
Retaining clip
Check for proper seating
11 -
To heat exchanger
12 -
Rear coolant line Diagram of coolant hose connections
Page 19
-17
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Page 17 of 34
19-16
20 -
Coolant line
Diagram of coolant hose connections
Page 19
-17
21 -
Bleeder screw
Tightening torque: 20 Nm
22 -
Banjo bolt Tightening torque: 35 Nm
23 -
Left coolant line From turbocharger to rear coolant line
24 -
Sender for auxiliary water pump 2-pinIf necessary, release pressure in cooling
system before removing
25 -
To oil cooler
26 -
Retaining clip Check for proper seating
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