Volkswagen Chapter 3 Cooling heating and air conditioning systems

Air conditioning system compressor – drivebelt adjustment . . . . . . . 12
Air conditioning system compressor – removal and refitting . . . . . . . 11
Coolant pump – removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 6
Cooling fan and motor- removal and refitting . . . . . . . . . . . . . . . . . . 4
Cooling system – draining, flushing and filling . . . . . . . . . . . . . . . . . . 2
Cooling system electrical switches – removal, testing and refitting . . 7
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Heat exchanger/fresh air box – removal and refitting . . . . . . . . . . . . 10
Heater and fresh air blower unit – removal and refitting . . . . . . . . . . 9
Heater controls – removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 8
Radiator – removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 3
Thermostat – removal, testing and refitting . . . . . . . . . . . . . . . . . . . . 5

Cooling system
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised with pump driven by timing or V-belt. Front mounted
radiator with internal or external expansion tank. Electric cooling fan
Radiator/expansion tank
Cap operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 to 1.5 bar
Thermostat
Minimum stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 mm
Opening temperature:
1.05 and 1.3 litre engines:
Rocker finger tappet type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92°C
Hydraulic tappet type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87°C
1.6 and 1.8 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85°C
Fully open temperature:
1.05 and 1.3 litre engines:
Rocker finger tappet type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108°C
Hydraulic tappet type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102°C
1.6 and 1.8 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105°C
Cooling fan thermo-switch
Carburettor engines:
Switch-on temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93° to 98°C
Switch-off temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88° to 93°C
Fuel injection engines (except 16 valve):
Switch-on temperature:
Single speed and 1st stage of twin speed . . . . . . . . . . . . . . . . . . . 92° to 97°C
2nd stage of twin speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99° to 105°C
Switch-off temperature:
Single speed and 1st stage of twin speed . . . . . . . . . . . . . . . . . . . 84° to 91°C
2nd stage of twin speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91° to 98°C
Injector cooling:
Switch-on temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110°C
Switch-off temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103°C
Air conditioning system compressor – drivebelt adjustment . . . . . . . 12
Air conditioning system compressor – removal and refitting . . . . . . . 11
Coolant pump – removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 6
Cooling fan and motor- removal and refitting . . . . . . . . . . . . . . . . . . 4
Cooling system – draining, flushing and filling . . . . . . . . . . . . . . . . . . 2
Cooling system electrical switches – removal, testing and refitting . . 7
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . 1
Heat exchanger/fresh air box – removal and refitting . . . . . . . . . . . . 10
Heater and fresh air blower unit – removal and refitting . . . . . . . . . . 9
Heater controls – removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 8
Radiator – removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 3
Thermostat – removal, testing and refitting . . . . . . . . . . . . . . . . . . . . 5
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