Volkswagen Workshop Service and Repair Manuals

Removing and installing thermostat

Special tools and workshop equipment required

t	10 mm jointed spanner -3185-

t	Refractometer -T10007-

t	Special wrench, long reach -T10058-

t	Torque wrench -V.A.G 1331/-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6340-

»Carry out the following work sequence« Removing   Note Renew gaskets and seals. –  Drain coolant → Chapter.

–  Remove bolts -arrows-. –  Free coolant hose -3-. –  Disconnect electrical connection -1- on charge pressure sender -G31-/intake air temperature sensor -G42- and remove right charge air pipe.

–  Disconnect coolant hose from union, loosen hose clip -1- for this. –  Loosen union securing bolts -arrows- using T-bar and 10 mm socket -3185- and unscrew with 5 mm Allen key extension -T10058- and remove union with thermostat -1-.

–  Turn thermostat -2- approx. 15° clockwise -arrow- and remove from union. –  Remove O-ring -1-. Installing l  Specified torque → Chapter. Installation is carried out in the reverse order; note the following:   Note t  Renew O-ring. t  Hose unions and air intake pipes/hoses must be free of oil and grease when installing. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Clean and smoothen sealing surface for O-ring. –  Moisten O-ring with coolant.

–  Insert thermostat -3- with O-ring -2- in guides on union -1-.

–  Turn thermostat -1- anticlockwise -arrow- to stop. –  Install charge air pipe. –  Golf, Golf Plus, Passat: Re-install connecting hoses with screw-type clips → Rep. gr. 21 „Turbocharging/supercharging“ –  Polo: Install connecting hoses with screw-type clips → Chapter. –  Replenish coolant → Chapter.