Volkswagen Workshop Service and Repair Manuals

Thermostat side

• Retainer
• ◆ For connectors
• Self-tapping bolt
• From bottom of radiator
• ◆ Coolant hose connection diagram
• Connection
• O-ring
• ◆ Renew
• Coolant thermostat
• ◆ Checking operation: heat-up thermostat in water the thermo element pin must move out
• ◆ Temperature check: Opening starts (approx. 84 °C) and ends (approx. 98 °C) cannot be checked.

• To top of expansion tank
• To heat exchanger
• From expansion tank or ATF cooler
• Retaining clip
• From heat exchanger
• Coolant pump housing on cylinder block
• Seal
• ◆ Renew
• Coolant pipe
• Thermostat housing
• 10 Nm

• Sealing plug/connection for ATF cooler
• Coolant temperature sender (G62)
• ◆ With coolant temperature gauge sender (G2)
• To top of radiator
• ◆ Coolant hose connection diagram

Coolant pump side

• Main drive toothed belt
• ◆ Mark D.O.R. before removing
• ◆ Check for wear
• ◆ Do not kink
• ◆ Toothed belt routing , Fig. 1
• ◆ Removing, installing and tensioning
  => Page 13-14
• Coolant pump
• ◆ Check for ease of movement
• ◆ If damaged or leaking renew complete
• ◆ Removing and installing
  => Page 19-18
• 10 Nm
• Rear toothed belt guard
• Toothed belt guard - upper part
• Toothed belt guard - lower part

• Belt pulley
• ◆ When installing note fixing arrangement
• ◆ Removing and installing ribbed belt => Page 13-11
• 90 Nm + 1/4 turn (90 °) further
• ◆ Renew
• ◆ Oil threads
• ◆ The turning further can be done in several stages
• ◆ The turning further angle can be checked with a commercial protractor e.g. Hazet 6690
• 12 Nm
• ◆ Renew
• 20 Nm
• Crankshaft toothed belt sprocket
• ◆ When installing note fixing arrangement