Volkswagen Touareg (2003 year). Manual - part 23

Removing
– Drain coolant 

⇒ page 86

 .

– Pull out retaining clips from quick-release coupling for coolant

hose at top and bottom and detach coolant hoses from radia‐

tor.

gr.  63 ; Assembly overview - front bumper

– Remove fans with fan support 

⇒ page 79

 .

– Loosen securing clips for condenser and ATF cooler.
– Remove upper securing bolts for radiator and remove radiator

upwards.

Installing
Installation is carried out in the reverse order. When installing,

note the following:
– Replenish coolant 

⇒ page 86

 .

– Electrical connections and routing ⇒ Current flow diagrams,

Electrical fault finding and Fitting locations.

– Install front bumper: ⇒  General body repairs, exterior; Rep.

gr.  63 ; Assembly overview - front bumper

– Check headlight adjustment and correct if necessary ⇒ Main‐

tenance ; Booklet  17.1 .

1.11

Removing and installing coolant pump

and thermostat

Special tools and workshop equipment required
♦ Drip tray -V.A.G 1306-

Touareg 2003 ➤

1. Removing and installing parts of cooling system    

89

Removing
– Drain coolant 

⇒ page 86

 .

– Remove upper coolant hose from thermostat housing.
– Remove radiator fans with radiator fan support 

⇒ page 79

 .

– Remove poly V-belt 

⇒ page 18

 .

– Remove toothed belt 

⇒ page 34

 .

If thermostat must be renewed:
– Unscrew securing bolts of thermostat housing -arrows-.
– First remove seal and then thermostat.
Installing

– Insert thermostat with bleeder valve -arrow- facing upwards.
– Moisten new O-ring with coolant and install it.
– Install thermostat housing by first screwing in all securing bolts

by hand and then tightening all bolts to specified torque of 10

Nm.

If coolant pump must be renewed:

Touareg 2003 ➤

90

note the following:
– Insert coolant pump with gasket.
– Screw in all securing bolts by hand and tighten to specified

torque. Specified torque: 15 Nm

– Reinstall toothed belt 

⇒ page 34

 .

– Install poly V-belt 

⇒ page 18

 .

– Replenish coolant 

⇒ page 86

 .

1.12

Checking cooling system for leaks

Special tools and workshop equipment required
♦ Cooling system tester -V.A.G 1274-

♦ Adapter for cooling system tester -V.A.G 1274/8-

♦ Adapter for cooling system tester -V.A.G 1274/9-
– Screw cooling system tester -V.A.G 1274- with adapter -V.A.G

1274/8- onto expansion tank.

– Operate pump on tester and build-up pressure of between 1.4

and 1.6 bar.

– Check cooling system tester for leaks.
– In addition, check sealing cap.

Touareg 2003 ➤

1. Removing and installing parts of cooling system    

91

the adapter for cooling system tester -V.A.G 1274/9- on seal‐

ing cap as shown.

– Operate pump on tester and create a pressure of between 1.6

bar.

– The pressure relief valve in the sealing cap must remain

closed for the time being.

– If valve opens before test is complete, renew sealing cap.

Touareg 2003 ➤

92