Volkswagen Workshop Service and Repair Manuals

Removing and installing front coolant pipe Special tools and workshop equipment required

t  Removal lever -80 - 200-

t  Hose clip pliers -VAS 6362-

Removing –  Drain coolant → Chapter. –  Remove air filter housing → Chapter. –  Remove oil filter bracket with engine oil cooler → Chapter

–  Country-specific version for cold countries: Disconnect electrical connector -2-. –  Remove crankcase breather hose -1-, press release buttons for this. –  Pull off vacuum hose -arrow-. –  Unscrew bolt -3-, swing air pipe with inlet connection to rear and pull off from turbocharger.   Note Disregard -item 4-.

–  Unclip wiring harness from retainer -arrow-.

–  Free wiring harnesses -arrows- and electrical connector -1- at bracket.

–  Remove air intake hose. To do this, loosen hose clips -1, 2-.

–  Remove bolts -arrows-. –  Free electrical wiring and hoses on left air pipe using removal lever -80 - 200-. –  Loosen hose clip -1- and remove left air pipe.

–  Disconnect coolant hoses and free them, loosening hose clips -1- to do so.   Note Disregard -items 2, 3, 4-

–  Remove electrical connector -2- for Hall sender -G40- from retainer and separate. –  Remove bracket from front coolant pipe. –  Remove coolant hoses, loosening hose clips -1- and -3- to do so. –  Undo bolts -arrows- and pull front coolant pipe off cylinder block towards the left. Installing Installation is carried out in the reverse order; note the following: l  Specified torques → Chapter.   Note t  Renew gaskets, seals and O-rings. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Clean or smoothen sealing surface for O-ring. –  Moisten O-ring with coolant and slide onto front coolant pipe. –  Push front coolant pipe into cylinder block. –  Installing intake hoses with screw-type clips → Fig.. –  Install charge air pipe → Chapter. –  Install air pipe with inlet connection. –  Install oil filter bracket with engine oil cooler → Chapter. –  Install air filter housing → Chapter. –  Replenish coolant → Chapter.