Contents - Volkspage

Cooling, heating and ventilation systems 3.3
3.5a Removing the radiator upper
mounting screws
inspection
8 If the radiator has been removed due to
suspected blockage, reverse flush it as
described in Chapter 1. Clean dirt and debris
from the radiator fins, using an air line (in
which case, wear eye protection) or a soft
brush. Be careful, as the fins are easily
damaged, and are sharp.
9 If necessary, a radiator specialist can
perform a “flow test” on the radiator, to
establish whether an internal blockage exists.
10 A leaking radiator must be referred to a
specialist for permanent repair. Do not
attempt to weld or solder a leaking radiator,
as damage may result.
11 In an emergency, minor leaks from the
radiator can be cured by using a suitable
radiator sealant in accordance with the
manufacturers instructions with the radiator in
situ.
12 If the radiator is to be sent for repair or
renewed, remove the thermostatic switch.
Refitting
13 Refitting is a reversal of removal, but if
necessary renew the radiator mounting
rubbers. Fill the cooling system as described
in Chapter 1.
Removal
1 The thermostat is located in the outlet
housing on the left-hand end of the cylinder
head. To remove it, first drain the cooling
system as described in Chapter 1.
2 Unscrew the bolts and remove the
thermostat cover (see illustrations). Place
the cover with top hose still attached to one
side.
3 Remove the sealing ring (see illustration).
4 Extract the thermostat from the outlet
housing.
Testing
5 To test whether the unit is serviceable,
suspend it with a piece of string in a container
3.5b Removing the radiator upper
mounting rubbers
of water. Gradually heat the water and note
the temperature at which the thermostat
starts to open. Continue heating the water to
the specified fully open temperature then
check that the thermostat has opened by at
least the minimum amount given in the Specifications.
Remove the thermostat from the
water and check that it is fully closed when
cold.
6 Renew the thermostat if it fails to operate
correctly.
7 Clean the thermostat seating and the
mating faces of the outlet housing and cover.
Refitting
8 Refitting is a reversal of removal, but fit a
new sealing ring and tighten the cover bolts to
the specified torque. Fill the cooling system as
described in Chapter 1.
Testing
1 The cooling fan is supplied with current
through the ignition switch, fuse and radiator
thermoswitch which is mounted in the lefthand
end of the radiator. Either a single- or
two-stage fan is fitted. The two-stage fan has
two speed settings; the thermostatic switch
actually contains two switches one for the
stage 1 fan speed setting and another for the
stage 2 fan speed setting. Testing of the
4.2a Unscrew the socket head bolts. . .
cooling fan circuit is as follows noting that
where applicable the following check should
be carried out on both the stage 1 speed
circuit and the stage 2 speed circuit (see
wiring diagrams at the end of Chapter 12).
2 If the fan does not work, first check the
fuses. If they are good, run the engine until
normal operating temperature is reached,
then allow it to idle. If the fan does not cut in
within a few minutes, switch off the ignition
and disconnect the wiring plug from the
cooling fan thermoswitch. Bridge the relevant
two contacts in the wiring plug using a length
of spare wire, and switch on the ignition. If the
fan now operates, the switch is probably
faulty and should be renewed.
3 If the switch appears to work, the motor
can be checked by disconnecting the motor
wiring connector and connecting a 12 volt
supply directly to the motor terminals.
4 If the fan still fails to operate, check the
cooling fan circuit wiring with reference to
Chapter 12. Check each wire for continuity
and make sure all connections are clean and
free from corrosion. If the motor is faulty, it
must be renewed, as no spares are available.
Removal
5 Disconnect the battery negative lead. Note:
Make sure you know the anti-theft code for
the radio so that it can be re-activated when
the battery is reconnected.
6 Disconnect the wiring from the cooling fan
motor.
7 Remove the four screws and lift the cowling
together with the cooling fan and motor from
the radiator.
4.2b . . . and remove the thermostat cover 4.3 Removing the thermostat cover
sealing ring