Volkswagen Workshop Service and Repair Manuals

Removing and installing coolant pipes (front) Special tools and workshop equipment required

t  Hose clip pliers -VAS 6362-

t  Drip tray for workshop hoist -VAS 6208- Removing Proceed as follows:   WARNING When the engine is warm, the cooling system is under pressure. Hot steam/hot coolant can escape - risk of scalding. Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure. –  Open filler cap on expansion tank.

–  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct at bottom together with air hose.

Vehicles with sound generator: –  Open latch -1-, unclip fuel lines -2- and slacken bolts -3-. Remove charge air pipe. Vehicles with activated charcoal filter in engine compartment:

–  Pull off breather line -1-, release activated charcoal filter -A- and remove upwards -B-. Lay activated charcoal filter to side.

All: –  Loosen hose clip -2-. –  Remove bolt -4-. –  Disconnect electrical connector -arrow- and move electrical wires clear. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50

–  Remove air hose -items 1 and 2- and seal charge air cooler with a clean cloth.

–  Remove bolt -1- and take out air pipe downwards.

–  Place drip tray for workshop crane -VAS 6208- beneath engine. –  Disconnect coolant hoses from continued coolant circulation pump -V51--arrows-.

–  Unscrew bolts -1 and 2- and disconnect coolant pipes (front) from coolant hoses -arrows-. Installing l  Specified torques → Chapter. Installation is carried out in the reverse order. When installing, note the following:   Note t  Renew gaskets and seals. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → ETKA (electronic parts catalogue). –  Installing hose connections with connector couplings → Chapter.