Volkswagen Workshop Service and Repair Manuals

Removing and installing thermostat (extended circuit)

Special tools and workshop equipment required

t	Refractometer -T10007-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6340-

t	Cooling system charge unit -VAS 6096-

t	Adapter for cooling system tester -V.A.G 1274/8-

t  Refractometer -T10007 A-

t  Torque wrench -V.A.G 1331-

t  Torque wrench -V.A.G 1410- Removing –  Drain coolant → Chapter. –  Remove coolant pump -1- → Chapter.

–  Remove bolts -arrows-. –  Remove coolant pump -1- from thermostat housing -2-. –  Remove thermostat -3-. Installing Installation is carried out in the reverse order. When installing, note the following:

–  Fit thermostat to coolant pump. –  Centring pin of thermostat must be fitted into guide -arrow- on coolant pump.

–  Ensure proper seating of gaskets -arrows-. –  Moisten gasket with coolant.

–  Fit thermostat housing to coolant pump. –  Ensure proper seating of thermostat studs in guides -arrows- of coolant pump.

–  Thread and tighten securing bolts -A- through -F- in sequence given. –  Install coolant pump -1- → Chapter. –  Install selector mechanism to gearbox: → Rep. gr.34. –  Replenish coolant → Chapter. –  Install air filter housing → Chapter.

Specified torque:

Component	Specified torque
Thermostat housing to coolant pump	7 Nm
Coolant pump	12 Nm, observing tightening sequence → Chapter