Volkswagen Workshop Service and Repair Manuals

Removing and installing 4/2-way valve with thermostat   Note The thermostat is located within the 4/2-way valve and cannot be replaced individually.

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 –  Remove noise insulation → General body repairs, exterior; Rep. gr.50 –  Removing cowling with radiator fan -V7-.   Note Renew gaskets and seals. –  Remove engine cover panel → Chapter.

–  Disconnect electrical connector -1- from air mass meter -G70-. –  Pull off hose -3- on air filter housing. –  Loosen bolt -arrow 4-. –  Remove air filter housing together with air mass meter and suction hose . –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. gr.27. –  Remove battery and battery tray → Electrical system; Rep. gr.27.

–  Remove the generator → Electrical system; Rep. gr.27. –  Guide alternator with extreme caution past radiator to prevent damaging it.

–  Unclip wiring harness from bracket -arrow-.

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

–  Unscrew bolts -2, 5- and -arrows-. –  Free electrical lines and hoses on left air pipe using removal lever -80 - 200-. –  Release hose clip -3- and remove left air pipe.   Note Disregard -item 1, 4-. –  Drain coolant → Chapter.

–  Pull coolant hoses off. Release hose clips -1- for this.   Note Disregard -items 2, 3, 4-.

–  Remove electrical connector -1- for Hall sender -G40- from bracket. –  Unscrew bolts -arrows- and pull front coolant pipe to side away from 4/2-way valve.   Note Disregard -item 2, 3-.

–  Pull coolant pipe out of connection -C- for 4/2-way valve. Leave in its installation position.

–  Unscrew bolts -arrows-. –  Free coolant hose -3-. –  Release hose clip -2-. –  Disconnect electrical connector -1- on charge pressure sender -G31-/intake air temperature sender -G42- and remove right air pipe.

–  Unscrew bolt -1-. –  Press off clip -2- using removal lever -80 - 200-. –  Pull oil dipstick guide tube upwards out of cylinder block and press aside.

–  Remove throttle valve module -J338-.

–  Pull coolant hoses off unions -A, B and D-. –  Remove securing bolts -3- for 4/2-way valve -2-. –  Pull valve out from cylinder block. Installing –  Moisten new O-ring -1- with coolant.

–  Thread 4/2-way valve in past ancillary bracket in direction of oil filter module.

–  Insert union -2- of 4/2-way valve with O-ring -1- into cylinder block with slight rotary motions.

–  Thread coolant pipe into connection -C- for 4/2-way valve. Remaining installation is carried out in the reverse order. When installing, note the following:

–  Tighten securing bolts -3- using T-bar and 10 mm socket -3185-. Specified torque: 15 Nm. Specified torque for throttle valve module -J338- → Chapter. –  Replenish coolant → Chapter. –  Install throttle valve module -J338- → Chapter. –  Install alternator → Starter, current supply, CCS; Rep. gr.27. –  Installing charge air pipe → Chapter. –  Install poly V-belt → Chapter.