Procedures

Thermostat Removing and Installing




Special tools, workshop equipment, test and measuring appliances and aux. items required
- T10007
- Refractometer
- V.A.G 1306
- Drip tray
- V.A.G 1331 Torque wrench (5 to 50 Nm)
- VAS 5024 Assembly tool for spring type clamps




Cooling System Components (Engine Side)
1 Bolt. Torque Specification 15 Nm (11 ft. lbs.)
2 Toothed belt
4 O-ring - replace
5 Coolant thermostat
6 O-ring - Replace
7 Connection - to heat exchanger
9 O-ring - replace
10 4 pin Connector
11 Coolant Temperature Sender (G62)
12 Retaining clip - make sure it's seated securely
13 Upper coolant hose - secured to radiator with retaining clip
14 Lower coolant hose - secured to radiator with retaining clip
15 Oil cooler
16 From heat exchanger
17 Lower coolant pipe
18 Bolt. Torque Specification 10 Nm (7 ft. lbs.)
19 Cap. Test pressure 1.4-1.6 bar (20-23 psi)
20 Seal - replace if damaged
21 Bolt. Torque Specification 10 Nm (7 ft. lbs.)
22 Expansion tank
23 To turbocharger
24 Bolt 15 Nm (11 ft. lbs.)
25 To upper coolant hose - Only on engine code AWP with automatic transmission,
26 After-run coolant pump (V51) - Only on engine code AWP with automatic transmission.
27 From turbocharger - Only on engine code AWP with automatic transmission.

Removing
- Drain coolant. Refer to Cooling System, Service and Repair. Service and Repair




- Pull coolant hose off connecting flange
- Unbolt securing bolts -4- of connecting flange -3- and remove connecting flange-3-with thermostat -1-.

Installing
Installation is carried out in the reverse order, when doing this note the following:

Note: Always replace seals and gaskets.

- Moisten new O ring -2- with coolant.
- Insert thermostat -1- into connecting flange -3- and turn 1/4 turn (90°) to right.
- Install connecting flange -3- with thermostat -1- into engine block.

Note: The brace on the thermostat must be almost vertical.





- Tighten securing bolts -4-. Tightening torque: 15 Nm (11 ft. lbs.)
Fill with new coolant.