Cooling issue after water pump/thermostat replacement

Tiny
NAVYTOUAREGV8
  • MEMBER
  • 2004 VOLKSWAGEN TOUAREG
  • 4.2L
  • V8
  • 4WD
  • AUTOMATIC
  • 197,000 MILES
I changed the main water pump and thermostat and drained a few quarts of coolant from the engine. But when I finished and went to fill the coolant I could only put in 20oz of coolant and it still overheated. The coolant is not getting from the coolant tank to the engine or radiator. Could the auxiliary water pump failing cause this issue?
Monday, March 4th, 2019 AT 1:08 PM

6 Replies

Tiny
NAVYTOUAREGV8
  • MEMBER
  • 5 POSTS
I should be able to fill and burp the system through the coolant reservoir. It's stopped somewhere in the system.
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Monday, March 4th, 2019 AT 2:07 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi and thanks for using 2CarPros.

Yes, the coolant is filled at the reservoir. However, it is done using a special tool.

Fill coolant circuit using cooling system charge unit (VAS 6096). This tool basically fills the system using vacuum. However, you should be able to do it without the tool. See picture 1

Next, when you installed the thermostat, did you make sure to have the bleeder hole at 12oclock? See picture 2. If it isn't that will prevent bleeding.

Let me know.

Joe
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Monday, March 4th, 2019 AT 6:34 PM
Tiny
NAVYTOUAREGV8
  • MEMBER
  • 5 POSTS
Yes, I did make sure the bleeder is up on the thermostat and I think their is a blockage somewhere because no coolant is making it to the radiator and front hoses. I was reading about the Porsche Cheyenne with the same engine that had a aluminum coolant pipe defect that blocked the coolant. Also I can't find a diagram of the cooling system to know what comes after the coolant tank. That hose from the coolant tank gets crazy hot and I can hear gurgling and bubbling coming from the back side of the engine.
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Monday, March 4th, 2019 AT 6:45 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Interesting. You may have to use the vacuum tool to get it bleed. Here are the parts for the cooling system. See the attached pictures. The following indicates parts/numbers which are related to picture 1. Item 23 goes to the expansion tank (reservoir) which is indicated to be on the rear of the engine. Picture 3 shows the front of the engine (exploded view).

I have to be honest, I have worked on several 4.2L A8 vehicles. The cooling system runs everywhere around the engine. With that, what I think we may need to try is to first loosen the upper radiator hose to allow air to escape the radiator. Once coolant starts coming out, move to the heater core return. If you still can't get coolant throughout the system, you may have to get the tool.

1 Coolant line

Between right and left cylinder head

With junction to heat exchanger for heater, expansion tank and upper coolant hose.

2 O-ring

Replace

3 Engine Coolant Temperature (ECT) Sensor (G62)

With Engine Coolant Temperature (ECT) Gauge Sensor (G2)

For engine control module

If necessary release pressure in cooling system before removing

4 Coolant line

5 To coolant thermostat

6 20 Nm

7 Gasket

8 Coolant line

From cylinder head, bank 1

9 Coolant line

To oil filter housing

10 To expansion tank

11 To expansion tank

12 Coolant line

13 10 Nm

14 To top coolant hose

15 10 Nm

16 Side coolant pipe

At cylinder head bank 1

17 Coolant hose

18 From heat exchanger for heater unit

19 To heat exchanger for heater unit

20 Coolant line

21 10 Nm

22 Retaining clip

Check for secure seat

23 Connection

To expansion tank

24 10 Nm

_______________________

Let me know if any of this helps.

Joe
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Monday, March 4th, 2019 AT 8:08 PM
Tiny
NAVYTOUAREGV8
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I don't see any pictures or diagrams your describing.
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Monday, March 4th, 2019 AT 9:04 PM
Tiny
NAVYTOUAREGV8
  • MEMBER
  • 5 POSTS
Also, I keep asking people if a bad auxiliary water pump the little plastic external one, would cause a blockage if it was not working. It seems they made this cooking system a lot more complicated then was needed.
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Monday, March 4th, 2019 AT 9:07 PM

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