Coolant Thermostat

Special tools and workshop equipment required

Removing

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- 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 air duct and the intake air duct.

-- Remove the charge air pipe from the noise generator, if equipped. Refer to CHARGE AIR PIPE FROM NOISE GENERATOR .

-- Loosen the hose clamp -2-.

Fig 3: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolt -4-.

-- Disconnect the electrical connector -arrow-.

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

-- Free up the coolant hose -2- and electrical harness -1-.

Fig 4: Identifying Electrical Wiring Harness, Coolant Hose And Bolt

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-- Remove the bolt -arrow- and remove the bracket.

-- Remove the after-run coolant pump bracket bolt -2-.

Fig 5: Identifying After-Run Coolant Pump V51 Bracket Bolt -2-

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NOTE:

The after-run coolant pump stays in the installed position.

-- Remove the coolant hoses -1 and 2- and lay them aside.

Fig 6: Identifying Coolant Hoses

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-- Loosen the nut -2-, remove the bolt -1- and move the support for the intake manifold to the right.

Fig 7: Identifying Intake Manifold Support, Nut And Bolt

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-- Remove the oil separator. Refer to OIL SEPARATOR .

-- Remove the bolts -arrows- and remove the connecting piece. For the right bolt, the hex ball socket T10058 is useful.

Fig 8: Identifying Coolant Thermostat Housing Bolts

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-- Remove the coolant thermostat.

Installing

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

-- Clean the O-ring sealing surface.

-- Lubricate the O-ring with coolant.

-- Install the thermostat -4- into the coolant pump -5- and move it slightly forward -arrow-.

Fig 9: Identifying Thermostat, Housing And Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully install the connecting piece -3- ; while doing so, insert the centering pin -2- into the guide -1-.