Thermostat: Service and Repair

EDITOR NOTE!
This is an ALLDATA procedure. OE does not provide preliminary or associated procedures for this Service; it is important to read the entire article before starting repairs.

Engine Cooling Thermostat, removing and installing




Special tools, testers and auxiliary items required
- Refractometer T10007
- Drip Tray V.A.G 1306 or Drip Tray for VAS 6100 VAS 6208
- Torque wrench V.A.G 1331
- Spring-type clip pliers VAS 5024A

Removing
- Remove Ribbed Belt. Removal and Replacement
- Remove Viscous Fan.
- Drain cooling system.
- Obtain and record radio anti-theft code for vehicles with a coded radio.
- See Caution for disconnecting battery.
- Disconnect battery Ground (GND) strap with ignition switched off.
- Remove coolant hose between radiator and coolant reservoir.







- Remove top coolant hose between coolant pipe and radiator.




- Remove air hose between throttle valve control module (J338) and charge air cooler.



- If necessary, remove the throttle valve control module (J338).
- Unbolt generator from bracket.
- Disconnect wiring from generator.
- Remove Generator. Service and Repair




- If needed, remove the intake manifold support.
- Remove lower coolant line from the thermostat housing.



- Remove the bolts holding the thermostat housing to the engine block.



- Remove Thermostat.
- If necessary, remove the lower coolant line to the oil filter holder.

Installing

Install in reverse order, note the following:
- Replace O-ring.
- Clean and/or smooth O-ring sealing surface.
- Moisten new O-ring with coolant.

- Install ribbed belt. Removal and Replacement
- Fill cooling system.