Right coolant pipe, removing and installing

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Fig 1: Identifying Special Tools - Right Coolant Pipe, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Engine support bridge 10-222 A
Shackle 10-222 A/12
Hose clamp pliers VAS 6340
Insert pad for front fender T40045

Removing

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Drain coolant → Cooling system, draining and filling .
Bring lock carrier into service position → Lock carrier, moving into service position .

Fig 2: Removing Wiring Harness Bracket At Right Engine Plate

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Remove wiring harness bracket at right engine console - arrows -.

Fig 3: Removing Lower Nut On Right Engine Mount

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Remove lower nut - 1 - on right engine mount.

NOTE:

Ignore - 2 -.

Fig 4: Removing Rear Engine Cover

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Remove rear engine cover - arrows -.

Fig 5: Removing Front Engine Cover

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Remove front engine cover - arrows 1 and 2 -.

Fig 6: Removing Cover In Engine Compartment (Right Side)

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Remove cover - 1 - in engine compartment (right side).

Fig 7: Identifying Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct

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Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - item 1 - from air guide.
Remove bolts - arrows -.
Remove air duct - 2 -.

CAUTION: Note rules of cleanliness for working on the fuel injection system → Rules for cleanliness .

CAUTION: Fuel system is under pressure! Before opening system, place rags around connection area. Then release pressure by carefully loosening connection.

Fig 8: Installing/Removing Fuel Hose To/From Connection On Fuel Rail Line

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Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at hex head - 1 - and - 3 - and remove union nut - 2 -.

Fig 9: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air Guide Hose & Mass Air Flow (MAF) Sensor

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Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor G70.
Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.

Move wiring harness clear at air filter housing.
Remove clip and remove air filter housing with Mass Air Flow (MAF) sensor.

Fig 10: Disconnecting Vacuum Hose & Air Guide Hose From Throttle Valve Control Module

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Disconnect vacuum hose - 1 -.
Disconnect air guide hose - 2 - from throttle valve control module.

Fig 11: Disconnecting Vacuum Hose From Intake Manifold

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Disconnect vacuum hose - arrow - from intake manifold.

Fig 12: Disconnecting Hose For Crankcase Ventilation From Right Cylinder Head Cover

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Disconnect hose for crankcase ventilation from right cylinder head cover - arrow -.

Fig 13: Removing Bracket For Electrical Harness Connectors At Right From Bulkhead

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Remove electrical harness connectors - 1 to 4 - from bracket at right of bulkhead.
Free up cables.

Fig 14: Securing Shackle 10-222 A/12 To Right Rear Engine Lifting Eyelet

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Secure shackle 10-222 A/12 to right rear engine lifting eyelet.

NOTE:

Ignore - 1 -.

Fig 15: Engaging Shackle 10-222 A/12 On Spindle Of Engine Support Bridge 10-222 A

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Position engine support bridge 10-222 A onto bolted flange of fenders.
Engage shackle 10-222 A/12 on spindle of engine support bridge 10-222 A.
Raise engine slightly using spindle on engine support bridge.

Fig 16: Disconnecting Top Coolant Hose From Radiator

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Disconnect top coolant hose - arrow - from radiator.

Fig 17: Disconnecting Air Hose At Right On Engine

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Disconnect air hose - arrow - to combination valves for Secondary Air Injection (AIR).

Fig 18: Removing Bolts, Locating Hose Clamps And Removing Right Coolant Pipe From Coolant Hoses

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Remove bolts - 1 - and - 2 -.
Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.
If necessary, remove engine support bridge to remove coolant pipe.

Installing

Installation is in reverse order of removal, note the following:

NOTE:

Secure all hose connections using hose clamps appropriate for the model type .
During installation, all cable ties must be re-installed at the same location.

Fig 19: Installing/Removing Fuel Hose To/From Connection On Fuel Rail Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure fuel hose to connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 20: Placing Torque Support On Rubber Buffer For Torque Support

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Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Fill with coolant Filling .
Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

Torque specifications

Component	Nm
Right coolant pipe to cylinder head	10
Left engine mount to engine console	23
Oil pipes to rear air guide pipe	10
Fuel supply line to fuel rail	22
Torque support stop to lock carrier	28