Volkswagen Workshop Service and Repair Manuals

Thermostat side

Engine codes ABD, ABU

• O ring
• ◆ Renew
• Coolant temperature sender (G62)
• ◆ With coolant temperature gauge sender (G2)
• Retaining clip
• 20 Nm
• To expansion tank
• ◆  , Item 14
• Coolant pipe
• To heat exchanger
• Hexagon bolt, 10 Nm or self-tapping screw

• From heat exchanger
• From expansion tank
• ◆  , Item 12
• To top of radiator
• ◆  , Item 8
• Coolant thermostat
• ◆ Installation position => Fig. 1
• ◆ Checking: heat-up thermostat in water
• ◆ Opening commences approx. 84 °C
• ◆ Ends approx. 98 °C
• ◆ Opening lift min. 7 mm
• From bottom of radiator
• ◆  , Item 9
• Bracket
• Thermostat housing

Engine code AEA

• Self-tapping bolt
• Connection
• O-ring
• ◆ Renew
• Coolant thermostat
• ◆ Installation position => Fig. 2
• ◆ Checking: heat-up thermostat in water
• ◆ Opening commences approx. 84 °C
• ◆ Ends approx. 98 °C
• ◆ Opening lift min. 7 mm
• To expansion tank
• ◆  , Item 14
• From expansion tank
• ◆  , Item 12

• To heat exchanger
• From heat exchanger
• Seal
• ◆ Renew
• Coolant pipe
• Retaining clip
• Thermostat housing
• 10 Nm
• Coolant temperature sender (G62)
• ◆ With coolant temperature gauge sender (G2)
• Sealing plug
• To top of radiator
• ◆  , Item 8
• From bottom of radiator
• ◆  , Item 9

Engine code AEE, AEX, APQ

• Retainer
• ◆ For central connector
• Self-tapping bolt
• From bottom of radiator
• ◆  , Item 8
• 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 expansion tank
• ◆  , Item 14
• To heat exchanger
• From expansion tank
• ◆  , Item 12
• Retaining clip
• From heat exchanger
• Coolant pump housing on cylinder block
• Seal
• ◆ Renew
• Coolant pipe
• Thermostat housing
• 10 Nm

• Coolant temperature sender (G62)
• ◆ With coolant temperature gauge sender (G2)
• Sealing plug
• To top of radiator
• ◆  , Item 8

Coolant pump side

Engine codes ABD, ABU

• 10 Nm
• Rear toothed belt guard
• 10 Nm
• ◆ Install with D6
• Camshaft sprocket
• ◆ Note position when installing the toothed belt
  
• 80 Nm
• Toothed belt
• ◆ Check for wear
• ◆ Do not kink
• ◆ Removing and installing
  => Page 13-20
• Toothed belt guard - upper part

• Bolt M6: 10 Nm
  Bolt M8: 20 Nm
• ◆ Install with D6
• Coolant pump
• ◆ Check for ease of movement
• ◆ If damaged or leaking renew complete
• ◆ Ensure correct type (teeth on sprocket)
• ◆ To tension toothed belt loosen slightly and turn with screwdriver => Page 13-20
• O-ring
• ◆ If leaking and damaged renew
• ◆ Use oversize seal ø5 mm on reconditioned coolant pumps with "5" stamped in securing flange area

Engine code AEE, AEX, APQ

• O-Ring
• ◆ If leaking and damaged renew
• Coolant pump
• ◆ Check for ease of movement
• ◆ If damaged or leaking renew complete
• Rear toothed belt guard
• Camshaft sprocket
• ◆ Note position when installing the toothed belt
  => Page 13-20
• 20 Nm + 1/4 turn (90 °) further
• ◆ Renew
• 10 Nm
• ◆ Install with D6

• Toothed belt
• ◆ Check for wear
• ◆ Do not kink
• ◆ Tensioning toothed belts
  => Page 13-20
• Toothed belt guard - upper part
• 10 Nm
• Toothed belt guard - lower part
• 20 Nm
• Tensioner
• ◆ Tensioning toothed belts
  => Page 13-20

→ Fig.1     Thermostat installation position

Engine codes ABD, ABU

The thermostat bridge support -1- must align with the threaded holes in the housing.

→ Fig.2     Thermostat installation position

Engine code AEA

The thermostat bridge support must lie in the cut-out of the housing connection piece.