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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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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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Edition 08.96
Fuel Supply System20
Safety precautions when carrying out work on fuel supply system
Pay attention to the following points when removing and installing the fuel gauge sender or the fuel pump (fuel delivery unit) from the fuel tank: 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 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 sur-
face and cover over. Do not use fluffing cloths!
Carefully cover over or seal opened compo- nents 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.
In addition, ensure that no diesel fuel flows onto the coolant hoses. If this happens, the
hoses should be cleaned again immediately.
Replace any hoses which have suffered da- mage.