Front Coolant Pipes

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Torque Wrench V.A.G 1783
Drip Tray for VAS 6100 VAS 6208 or V.A.G 1306
Hose Clip Pliers VAS 6362

Removing

WARNING:

Risk of scalding due to hot steam and hot coolant:

The coolant system is under pressure when the engine is warm.
Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.

-- Open the coolant expansion tank cap.

-- Remove the cover for the air duct; disengage the side clips to do so -arrows-.

Fig 1: Identifying Air Duct Cover Slide Clips

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-- Unclip the air duct from the lock carrier air duct, disengage the clips to do so -arrows-.

Fig 2: Identifying Lower Air Guide Clips

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-- Remove both the intake air duct and the lower air duct.

-- Only vehicles with noise generator: Open the locking mechanism -1-, unclip the fuel lines -2- and loosen the bolt -3- on the Evaporative Emission (EVAP) canister. Move the charge air pipe aside.

Fig 3: Identifying Latch, Fuel Lines And Bolts

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-- Loosen the hose clamp -2-.

Fig 4: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolt -4-.

-- Disconnect the electrical connectors -arrow- and free up the electrical wire.

-- Remove the noise insulation. Refer to Description and Operation .

-- Disconnect the charge air hose by lifting the clamp -1- and loosening the hose clamp -2-.

Fig 5: Identifying Charge Air Hose And Clamps

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-- Seal off the connections on the charge air cooler with a clean cloth.

-- Remove the bolt -1- and remove the charge air pipe downward.

Fig 6: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Place the drip tray for VAS 6100 VAS 6208 or V.A.G 1306 under the engine.

Fig 7: Identifying After-Run Coolant Pump V51 Bracket Bolt -2-

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-- Remove the coolant hoses from the after-run coolant pump -V51- -arrows-.

-- Remove the bolts -1 and 2- and remove the front coolant pipes from the coolant hoses -arrows-.

Fig 8: Identifying Front Coolant Pipes, Coolant Hoses And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Installing

Tightening specifications, refer to COOLANT PIPES OVERVIEW .

Install in reverse order of removal. When doing this note the following:

Install only approved clamps for securing hose connections.

-- Charge air pipe, installing. Refer to CHARGE AIR HOSE AND PIPE, DISCONNECTING AND CONNECTING

-- Check the coolant level. Refer to DRAINING AND FILLING .