Field Remedy: 2796

Remedy:

In case of customer complaint replace the plastic water connector 
against a metal water connector.

Working Procedure:

 1. Release coolant system pressure

    Warning:
    Open surge tank cap CAREFULLY!

 2. Place basin underneath
 3. Drain coolant

    - Attach suitable hose to lower connector at cooling module

      Important:
      Drain coolant untill the surge tank is empty!

    - Close lower connector at cooling module
    - Remove hose from cooling module

 4. Branch-off coolant hose between coolant pump and throttle body
    (Picture I)

    Note:
    Branch-off coolant hose in the area (1).

 5. Cover poly-V-belt using a workshop cloth
 6. Remove coolanz hose from coolant pump (Picture II, 1)

    - Loosen clamp (2)

 7. Remove water connector from coolant pump (Picture III, 1)

    Note:
    If the water connector is broken-off, pull water connector out of 
    the coolant hose using a suitable tool.

 8. Rebore water connector out of coolant pump (Picture IV)

    Important:
    Rebore remaining plastic of the water connector CAREFULLY!

    Note:
    Rebore with slow rpm.
    Rebore in two steps.

    a) 5.0 mm
    b) 6.5 mm

 9. Recut thread in coolant pump (Picture V, 1)

    Important:
    Recut thread in the coolant pump CAREFULLY using a middle thread 
    cutter M8 (level II)!

10. Clean sealing surface (Picture VI, 1)

11. Install NEW water connector and NEW seal ring to coolant pump
    (Picture VII, 1)

    - Tightening torque = 12 Nm

12. Install coolant hose to coolant pump

    - Fasten clamp

13. Remove fastener between coolant pump and throttle body
14. Remove worshop cloth
15. Correct coolant level
16. Clean upper and lower working area
17. Warm up engine

Spare-Parts:                            Part-No.:      Catalogue-No.:

Connector                               55564351       13 36 376
O-Ring, Connector                       55564569       13 36 377

Labour Times:                           TC:            Hours:

U3 279 60      Coolant pump water       90             0.5
               connector replacement

The costs for this repair will be covered during warranty and policy.
For policy please refer to the Policy Guideline (WebPG/Kuugel).
The regular Warranty Procedure will apply.