Volkswagen Touareg (2003 year). Manual - part 20

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.

♦

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

 .

Touareg 2003 ➤

1. Removing and installing parts of cooling system    

77

Assembly overview - radiator

1 - Coolant pipe

❑ Secured to fan support

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.

Touareg 2003 ➤

78

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
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.

Touareg 2003 ➤

1. Removing and installing parts of cooling system    

79

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.

Touareg 2003 ➤

80