Touran 2003 ➤

4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

19 – Cooling
1 Parts of cooling system

Caution agen
AG. Volkswagen AG d
oes
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♦ When doing any repair work, especially in the engine
rised com‐ nte
partment, pay attention to the following due ato
ut the cram‐
ho eo
ra
ped conditions: ss c

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le
un
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

pt
an
vated charcoal filter system, coolant, refrigerant, brake d
itte

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fluid and vacuum) and electrical wiring in their original po‐

ab
pe

ility
sitions.
ot

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♦ To avoid damage to lines, ensure sufficient clearance to

h re
hole

all moving or hot components.

spec
es, in part or in w

t to the co

satelettronica
Note

rrectness of i
l purpos

♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.

nform
ercia

♦ Hoses are secured with spring-type clips. In case of repair,

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a
com

only use spring-type clips.

tion in
r
te o

♦ Spring-type clip pliers -VAS 5024A- are recommended for in‐

thi
s
stallation of spring-type clips.
iva

do
r
rp

cum
fo

♦ When installing coolant hoses, route stress-free so that they

en
ng

t.
do not come into contact with other components (observe
yi Co
op
markings on coolant connection and hose).
C py
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Test for leaks in cooling system using cooling system tester - Prote
cted AG.
agen
V.A.G 1274- and adapters -V.A.G 1274/8- and -V.A.G 1274/9- .
Assembly overview - parts of cooling system - body side
⇒ page 79 .
Assembly overview - parts of cooling system - engine side
⇒ page 80 .
Coolant hose schematic diagram ⇒ page 81 .
Draining and filling with coolant ⇒ page 82 .
Removing and installing radiator fan -V7- and radiator fan 2 -
V177- ⇒ page 84
Removing and installing radiator ⇒ page 86 .
Removing and installing coolant pump ⇒ page 87 .
Removing and installing coolant circulation pump -V50-
⇒ page 91 .

78 Rep. Gr.19 - Cooling

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

1.1 Assembly overview - parts of cooling system, body side

1 - Radiator
❑ Removing and installing
⇒ page 86 .
❑ If renewed, change
coolant in entire system.
2 - O-ring
❑ Renew if damaged.
3 - Upper coolant hose
❑ To connection on cylin‐
der head.
❑ Coolant hose schematic
diagram ⇒ page 81 .
olkswagen AG
en AG. V
4 - Expansion tank ksw
ag does
not
y Vol gu
❑ Carry out leakage ed
b test in ara
nte
ris
cooling system
tho using eo
au
coolingsssystem tester - ra
c

satelettronica
V.A.G 1274- and adapt‐

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le
un

er for cooling system

pt
an
d
itte

tester -V.A.G 1274/8- .

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rm

ab
pe

5 - Connector
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6 - Cap
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❑ Check using cooling spec

es, in part or in w

system tester -V.A.G

t to the co
1274- and adapter for
cooling system tester -
V.A.G 1274/9- .
rrectness of i

❑ The pressure relief

valve must open at a
l purpos

pressure of
1.4...1.6 bar.
nform
ercia

7 - 5 Nm
m

a
com

ti

8 - Plastic inserts
on in
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te o

❑ For securing bolts.

thi
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9 - Bracket
r
rp

cum
fo

❑ For radiator.
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t.
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op py
10 - Cowling t. C rig
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pyri by
11 - 5 Nm
co Vo
by lksw
cted agen
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12 - Radiator fan 2 -V177-
13 - Connector
14 - Radiator fan -V7-
❑ With radiator fan control unit -J293- .
15 - Bracket
❑ For connector.
16 - Lower coolant hose
❑ To connection for thermostat.

1. Parts of cooling system 79

 Touran 2003 ➤ AG. Volkswagen AG d
agen
4-cylinder injection
Volksw engine (1.4 l direct injection
oes
not engine, turbocharger) - Edition 01.2006
y gu
db ara
ise nte
17 - Securing cliptho
r eo
s au ra
c
18 - Radiators outlet coolant temperature sender -G83-

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nl

pt
du

19 - 5 Nm

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wit
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1.2 Assembly overview - parts of cooling

h re
hole

system, engine side

spec
es, in part or in w

t to the co
Thermostat side

rrectness of i
1 - Connection
l purpos

2 - O-ring
❑ Renew.

nform
ercia

3 - Spring
m

at
4 - Plunger
om

ion
c

in t
r

5 - Thermostat
o

his
ate

❑ Opening starts at 87 °C.

do
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p

cum
or

6 - Coolant temperature send‐

f

en
ng

t.
yi
er -G62-
Co
Cop py
t. rig
❑ If necessary, release yri
gh by
ht
pressure in cooling sys‐
op Vo
by c lksw
tem before removing
cted agen
Prote AG.

7 - Securing clip
❑ Check for secure seat‐
ing.
8 - Thermostat housing
9 - Seal
❑ Renew.
10 - To expansion tank
❑ Coolant hose schematic
diagram ⇒ page 81 .
11 - Connection
12 - Coolant pipe
❑ Coolant hose schematic
diagram ⇒ page 81 .
13 - Coolant pipe
❑ Coolant hose schematic
diagram ⇒ page 81 .
14 - 5 Nm
15 - From bottom of radiator
❑ Coolant hose schematic diagram ⇒ page 81 .
16 - To top of radiator
❑ Coolant hose schematic diagram ⇒ page 81 .

80 Rep. Gr.19 - Cooling

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

1.3 Coolant hose schematic diagram

1 - Expansion tank
2 - Intake manifold
3 - Heater unit heat exchanger
4 - Thermostat housing
5 - Engine oil cooler
6 - Radiator
7 - Coolant circulation pump -
V50-
❑ Removing and installing
⇒ page 91 .
8 - Turbocharger
❑ Removing and installing
⇒ page 126 .
9 - Cylinder head/cylinder

satelettronica
block
❑ If renewed, renew cool‐
ant.
10 - Auxiliary heater agen
AG. Volkswagen AG d
oes
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❑ Optional extra d byV
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or eo
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ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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fo

en
ng

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1. Parts of cooling system 81

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

1.4 Draining and filling coolant

Special tools and workshop

equipment required
♦ Refractometer -T10007-
♦ Spring-type clip pliers -VAS
5024A-
♦ Cooling system charging
unit -VAS 6096-

satelettronica
AG. Volkswagen AG d
agen oes
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d
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wit
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h re
ole,

spec
urposes, in part or in wh

t to the co

Draining
rrectnes

WARNING
s o
cial p

f inform

Steam may escape when expansion tank is opened. Wear eye

mer

protection and protective clothing to avoid eye injuries and

atio
m

scalding. Cover cap with cloth and open carefully.

o

n
c

i
or

n thi
te

sd
iva

– Remove cap from coolant expansion tank.

o
pr

cum
r
fo

en
ng

– Remove engine splash guard.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

82 Rep. Gr.19 - Cooling

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

– Pull retaining clip out -arrow- and remove coolant hose from
radiator.

Note

Observe environmental regulations for disposal.

Filling

Note

♦ Use only coolant additive G12 in accordance with

“TL VW 774 F”. Identification: purple colour.
♦ G12 purple conforming with “TL VW 774 F” can be mixed with
the previous coolant additive G12 red!
♦ G12 and coolant additives marked conforming to
“TL VW 774 F” prevent frost and corrosion damage, scaling
and also raise boiling point of coolant. Therefore, the system
must be filled all year round with frost and corrosion protection

satelettronica
additives.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
. Volkswagen AG
gen AG
♦ Frost protection is required down toVoabout
lksw -25 °C (in countries es not
a o d
with arctic climates: down to about
ed
by -35 °C). gu
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♦ tho
The coolant concentrationaumust not be reduced by adding wa‐ eo
ra
ter even in warmer seasons
ss and in warmer countries. The anti- c
freeze must be at least 40% of mixture.
ce
e
nl

pt
du

an
itte

♦ If for climatic reasons greater frost protection is required, the

y li
erm

ab
amount of G 12 can be increased, but only up to 60% (frost
ility
ot p

protection to about -40°C). Otherwise frost protection and

wit
, is n

cooling effectiveness are reduced again.

h re
hole

♦ If radiator, heat exchanger, cylinder head or cylinder head

spec

gasket is replaced, do not reuse old coolant.

es, in part or in w

t to the co

Recommended mixture proportions:

rrectness of i

Frost Anti-freeze G 129) Water9)

protection to proportion
l purpos

-25 °C 40 % 2.25 l 3.35 l

-35 °C 50% 2.8 l 2.8 l
nf
ercia

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9) The quantity of coolant can vary depending upon vehicle equipment.

atio
om

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or c

– Press union against radiator and push retaining clip -arrow-

thi
te

sd

into groove.
iva

o
r
rp

cu
o

– Install engine splash guard.

m
f

en
ng

t.
yi Co
With cooling system charge unit -VAS 6096- Cop py
ht. rig
rig ht
– Fill coolant circuit using cooling system charge unit - py by
co Vo
by lksw
VAS 6096- ⇒ Operating instructions for cooling system filler Prote
cted AG.
agen
unit VAS 6096 .
Without cooling system filling unit -VAS 6096-

1. Parts of cooling system 83

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

– Fill with coolant up to max. mark on expansion tank.

With and without cooling system filling unit -VAS 6096-
– Fit expansion tank cap.
– Turn off heater control.
Vehicles without auxiliary heater
– Start engine and maintain an engine speed of about 2000 rpm
for about 3 minutes.
– Run engine until radiator fan -V7- cuts in.
Vehicles with auxiliary heater

Caution n AG. Volkswagen AG do

lkswage es n
o ot g
byV ua
ed ran
The auxiliary heater must only hor be switched on when the coolant
is tee
circuit is filled, describeds aas
u follows:
t or
ac
s

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e
nl

pt
du

an
itte

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– Connect Vehicle diagnosis, testing and information system -
erm

ab

satelettronica
VAS 5051 A- as follows:

ility
ot p

wit
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– Push diagnosis cable connector onto diagnosis connector in

h re
driver footwell.
hole

spec
es, in part or in w

– Start engine and maintain an engine speed of about 2000 rpm

t to the co
for about 3 minutes.
– Press buttons on display one after the other for “Vehicle self-

rrectness of i
diagnosis”, “18 - Auxiliary heater” and “03 - Final control diag‐
nosis”.
l purpos

– Press right arrow button on display up to final control diagnosis

for heater coolant shut-off valve -N279- .
nform
ercia

– Initiate final control diagnosis for heater coolant shut-off valve

m

at

-N279- . Continue to maintain engine speed at 2000 rpm for

om

ion

approx. 1 minute.
c

in t
or

his
te

– Run engine until radiator fan -V7- cuts in.

a

do
priv

cum
or

Continuation for all vehicles

f

en
ng

t.
yi Co
Cop py
WARNING
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Steam may escape when expansion tank is opened. Wear eye
agen
Prote AG.
protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.

– Check coolant level and top up if necessary. When the engine

is at normal operating temperature, the coolant level must be
on the max. mark; when the engine is cold, between the min.
and max. marks.

1.5 Removing and installing radiator fan -

V7- and radiator fan 2 -V177-
Removing radiator fan
– Remove engine cover.

84 Rep. Gr.19 - Cooling

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

– Remove upper securing bolts of cowling -arrows-.

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Body front; Noise insulation.

– Disconnect connector -1- and remove lower securing bolts of

cowling -arrows-.
– Remove cowling downwards.

AG. Volkswagen AG d
agen oes
lksw not

satelettronica
Vo gu
by ara
d
rise nte
tho eo
au ra
ss c

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nl

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itte

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– Disconnect electrical connection -1- and free wiring.
erm

ab
ility
ot p

– Remove nuts -arrows- and remove fans.

wit
, is n

h re
Install radiator fan.
hole

spec
Installation is carried out in the reverse order. When installing,
es, in part or in w

t to the co
note the following:
Torque settings:

rrectness of i
Component Nm
l purpos

Radiator fan to cowling 10

Cowling to radiator 5
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Parts of cooling system 85

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

1.6 Removing and installing radiator

Special tools and workshop

equipment required
♦ Refractometer -T10007-
♦ Spring-type clip pliers -VAS
5024A-
♦ Torque wrench (5..0.50
Nm) -V.A.G 1331-

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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nl

pt
du

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itte

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erm

ab
ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
Removing
– Bring lock carrier into service position ⇒ General body repairs, rrectness of i
exterior; Rep. Gr. 50 ; Body, front; Lock carrier - service po‐
l purpos

sition .
nf

– Drain coolant ⇒ page 82 .

ercia

orm
m

– Pull coolant hoses off radiator.

atio
om

n in
c

– Pull connectors off thermal switch and radiator fan.

or

thi
te

sd
a

– Remove radiator securing bolts and remove radiator with fan

iv

o
r
rp

cu

downwards.
o

m
f

en
ng

t.
yi Co
Cop py
t.
Note
rig
gh ht
pyri by
Vo
o
by c lksw
cted
To prevent damage to condenser and also to refrigerant lines/
agen
Prote AG.
hoses, ensure that the lines and hoses are not stretched, kinked
or bent.

– Remove retaining clamp(s) for refrigerant lines.

86 Rep. Gr.19 - Cooling

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
nte Touran 2003 ➤
ed
ris
o eo
4-cylinder injection engine
aut (1.4 l direct injection engine, turbocharger) - Edition
h
ra 01.2006
ss c

ce
e
– Unbolt condenser from radiator and secure to lock carrier.

nl

pt
du

an
itte

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Installing

erm

ab
ility
ot p
Installation is carried out in the reverse order. When installing,

wit
, is n
note the following:

h re
hole
Filling with new coolant ⇒ page 82 .

spec
es, in part or in w

t to the co
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.

1.7 Removing and installing coolant pump

rrectness of i
l purpos

Special tools and workshop

equipment required

nf
ercia

orm
♦ Refractometer -T10007-
m

atio
om

♦ Spring-type clip pliers -VAS

n in
or c

5024A-

thi
te

sd
iva

o
♦ Torque wrench (5..0.50
r
rp

cu
o

m
Nm) -V.A.G 1331-
f

en
ng

t.
yi Co

satelettronica
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note

Coolant pump with magnetic clutch for supercharger -N421- can

only be renewed complete.

Removing
– Drain coolant ⇒ page 82 .

1. Parts of cooling system 87

 AG. Volkswagen AG d
agen oes
olksw not
yV gu
Touran 2003 ➤ ed b ara
nte
ris
4-cylinder injection engine (1.4 l direct injectionut
h engine, turbocharger) - Edition 01.2006
o eo
ra
s a c
s
– Disconnect fuel supply line -1- and line to activated charcoal

ce
le
un

pt
cannister -2-. Press release buttons to do this.

an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos
– Unscrew hose clamp -1- from charge air pipe.

nform
ercia

– Unscrew securing bolt for charge air pipe -2-.

m

a
com

tio
– Remove front right wheel housing liner ⇒ General body re‐

n in
r

pairs; Rep. Gr. 66 ; Removing and installing wheel housing

te o

thi
liner; Front wheel housing liner .

s
iva

do
r
rp

cum
– Remove poly-V-belt ⇒ page 19 .
fo

en
ng

t.
yi

satelettronica
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Press securing clip on charge air cooler in

-direction of arrow- and pull hose -arrow- off.

– Unscrew securing bolt for charge air pipe -arrow- and remove
charge air pipe -1- downwards.

88 Rep. Gr.19 - Cooling

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

– Slacken compressor poly-V-belt by swinging tensioning ele‐

ment in -direction of arrow- with a spanner.
. Volkswagen AG
does gen AG
– Lock tensioning elementVol
ina position with locking
ksw pinno-T10060
t gu
A- . ed by ara
ris nte
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ra
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ss

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le
un

pt
an
d
itte

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ab
pe

ility
ot

wit
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h re
hole

spec
es, in part or in w

– Unscrew securing bolts -arrows- for tensioning element and

t to the co
remove tensioning element.
– Tightly hold compressor shaft with a spanner -1-.

rrectness of i
l purpos

nform
ercia

satelettronica
m

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

– Remove securing bolt -2- for pulley and remove pulley and
en
ng

t.
yi
compressor poly-V-belt -3-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Parts of cooling system 89

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

– Loosen bolts for coolant pump with magnetic clutch for super‐
charger -N421- -arrows-.
– Remove coolant pump with magnetic clutch for supercharger
-N421- from cylinder block.
Installing
Installation is carried out in the reverse order. When installing,
note the following:
– Insert coolant pump with magnetic clutch for supercharger -
N421- into cylinder block.
– Tighten securing screws to 8 Nm.
Torque settings:
Part I Assembly overview - belt drive ⇒ page 16
AG. Volkswagen AG d
Assembly overview - compressor ⇒ page 133 agen oes
olksw not
byV gu
ara
Assembly overview - charge air system ⇒ page 141 rised
nte
ho eo
ut
– Installing poly-V-belt ⇒ page 19 . ss a ra
c

ce
e

– Install front right wheel housing liner ⇒ General body repairs;

nl

pt
du

satelettronica
an
Rep. Gr. 66 ; Removing and installing wheel housing liner;
itte

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Front wheel housing liner .
erm

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ility
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– Fill with coolant ⇒ page 82 .

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
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m

atio
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or c

thi
te

sd
iva

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f

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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

90 Rep. Gr.19 - Cooling

 AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Touran 2003 ➤
e
4-cylinder horisinjection engine (1.4 l direct injection engine,
nte
e o turbocharger) - Edition 01.2006
aut ra
s s c
1.8 Removing and installing coolant circulation pump -V50-

ce
e
nl

pt
du

an
itte

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erm

ab
Special tools and workshop

ility
ot p

equipment required

wit
, is n

h re
♦ Refractometer -T10007-
hole

spec
♦ Spring-type clip pliers -VAS
es, in part or in w

t to the co
5024A-
♦ Torque wrench (5..0.50
Nm) -V.A.G 1331-

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

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for

en
g

satelettronica
n

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Remove securing bolts -arrows- for engine splash guard.
– Drain off coolant ⇒ page 82 .

1. Parts of cooling system 91

 Touran 2003 ➤
4-cylinder injection engine (1.4 l direct injection engine, turbocharger) - Edition 01.2006

– Remove spring clips -arrows- and pull coolant hoses off.

– Pull off connector -1- and unscrew securing bolt -2-. agen
AG. Volkswagen AG d
oes
olksw not
– Remove coolant circulation pump -V50- . ed by
V gu
ara
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Installing aut
ho eo
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Installation is carried out in the reverse order. When installing,

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un
note the following:

pt
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itte

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Specified torque setting for securing bolt: 10 Nm.

erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform

satelettronica
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
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en
ng

t.
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92 Rep. Gr.19 - Cooling