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Page 99 of 140
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19Cooling System
Edition 08.96
Installing coolant pipe
- Before installing, clean or smooth sealing
surface for O-ring.
- Moisten O-ring -1- with coolant and fit onto
coolant pipe -2-.
- Insert coolant pipe into the hole on the cylinder block.
- Bolt bracket for coolant pipe tight to 10 Nm-
Testing cooling system for leaks
Special tools, testers and aids required Cooling system tester (e.g. V.A.G 1274)
Adapter (e.g. V.A.G 1274/8)
Adapter (e.g. V.A.G 1274/9)
Test condition
Engine at operating temperature
Test procedure
Important! Hot vapours may escape when the expansionreservoir is opened. Cover over cap with cleaningrags and open carefully.
- Mount tester V.A.G 1274 with adapter V.A.G 1274/8 onto the expansion reservoir.
- Use the priming pump of the tester to produce a pressure of about 0.1 MPa.
- If the pressure drops, locate the leakage point and rectify fault.
Testing pressure relief valve in cap
- Screw cap onto the tester using adapter V.A.G 1274/9.
- Operate the priming pump of the tester to produce a pressure of about 0.15 MPa.
- The pressure relief valve should open at a pressure of 0.12 ... 0.15 MPa.
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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; Remov- ing 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 103 of 140
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Edition 11.96
Models with air conditioning
- Pull out radiator slightly together with con-
denser.
- 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 to10 Nm.
- On models with air conditioning, tighten the bolts for attaching condenser and brackets for 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; Remov- ing and installing headlights
- Electrical connections and routing: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
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