Volkswagen Workshop Service and Repair Manuals

Removing and installing thermostat housing Special tools and workshop equipment required

t  Hose clip pliers -V.A.G 1921-

t  Drip tray for workshop hoist -VAS 6208- Removing –  Drain coolant → Chapter. –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. gr.27.

–  Pull off cover -1- for air duct. Disengage locking clasps on side to do this. –  Unclip air duct -2-.

–  Remove air filter housing with connection hose. To do this, unscrew bolt -A-, pull off connector -B- and detach spring-type clips -C-. Note marking -D- when reinstalling. –  Pull air filter housing off upwards.

–  Pull vacuum line -arrow- off intake manifold changeover actuator. –  Unscrew bolts -1- and -2- and remove actuator from intake manifold.

–  Detach electrical connector -arrow- from coolant temperature sender -G62-.

–  Detach secondary air hose at position indicated by -arrow-. –  Move air hose away from bracket.

–  Detach coolant hoses at positions indicated by -arrows-.

–  Unscrew bolts -arrows-. –  Pull bracket for coolant pipe of gearbox oil cooler towards the left. –  Swivel bracket for secondary air hose forwards.

–  Unscrew bolt -arrows- from wiring harness retainer.   Caution Use lever to push coolant pipe in direction of coolant pump when pulling off thermostat housing so that pipe is not pulled off as well.

–  Pull off thermostat housing -2-. To do this, use lever to push coolant pipe -1- in direction of coolant pump. Installing Installation is carried out in the reverse order. When installing, note the following:   Note Renew seals and gaskets. –  Fill with coolant → Chapter. –  Connect battery. Required measures → Rep. gr.27. Specified torques

Component	Nm
Thermostat housing to engine	10
Wiring harness bracket to engine	10
Air filter housing to body	10