Coolant thermostat, removing, installing and checking: Notes

Removing

NOTE:

Always replace seals and gaskets.
Obtain radio anti-theft code on vehicles with coded radio.
Secure all hose connections with hose clamps of the same type as those installed at the factory.

With the ignition switched off, disconnect the battery Ground (GND) strap.
Drain cooling system. Refer to Draining
Detach coolant hose at bracket for solenoid valves above alternator.

Fig 1: Identifying Electrical Change-Over Valve Connector, Intake Manifold Brackets & Dipstick Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt bracket for solenoid valves -2- and -3- in front of intake manifold and detach dipstick guide tube -4-.

Fig 2: Pulling Connector And Vacuum Hose Out Of Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull connector -3- and vacuum hose -1- out of bracket.
Lay bracket clear to the side without detaching remaining connections.

Fig 3: Thermostat Location

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hose from elbow connection -3-.
Remove bolts -4- and take off elbow connection, O-ring and thermostat -1-.

Installing

Clean and smooth down sealing surface for O-ring as required.
Insert coolant thermostat. Installation position: bowed metal strip on thermostat must be vertical.
Moisten new O ring with coolant G 012 A8 D.
Tighten bolts.

Fill up with coolant. Refer to Filling .

Tightening torque

Component		Nm
Elbow connection to cylinder block		15
Bracket for solenoid valves to intake manifold		10

After connecting battery terminals, enter anti-theft code for radio

Refer to Radio operating instructions

WARNING:

If a battery charger is used to give the engine an assisted start, there is a risk that the control modules in the vehicle will be damaged.

Close electric windows in front doors all the way to their top positions using electric switches.
Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
Set clock to correct time.
Interrogate DTC memory:

Refer to

01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AMU
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): ATC
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): AWP
01 ON BOARD DIAGNOSTIC (OBD) for 1.8 LITER 4-CYL. 5V TURBO FUEL INJECTION & IGNITION, ENGINE CODE(S): BEA

; On Board Diagnostic , checking and erasing DTC memory

NOTE: DTCs will have been stored in the memory because connectors have been disconnected. Therefore interrogate and erase DTC memory after installing engine.