Thermostat: Service and Repair

MAP Controlled Thermostat

Special tools, testers and auxiliary items required

• Drip tray for workshop crane (VAS 6208)

• Hose clamp pliers (V.A.G 1921)

• Locking Tool (T40098)

Removing

CAUTION!
Observe measures when connecting battery.

- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.





- Remove engine cover - arrows -.





CAUTION!
Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

- Open cap of coolant expansion tank.

- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.





- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.





- Drain engine coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures

- Remove oil pressure sensor electrical connector - 1 -.





- Also remove lower coolant hose on coolant pipe - 2 - and allow remaining coolant to drain.

- Pull EVAP canister with connected lines upward in direction of - arrow - out of retainer and lay it aside.





• Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

- Mark direction of rotation of ribbed belt.

- Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.





- Secure tensioning element using Locking Tool ( T40098).

- Remove ribbed belt.

- Remove ribbed belt tensioner with engine lifting eye - arrows -.





- Remove generator.

- Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.





CAUTION!
The air conditioning refrigerant circuit must not be opened.

- Remove air conditioning compressor from bracket - arrows -.

• To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

- Hang up A/C compressor with attached lines at bottom of vehicle.

- Remove coolant hose - 2 -, thereby pull out retaining clip - 1 -.





- Remove accessory assembly bracket - bolts - 1 to 6 -.





- Disconnect electrical connector - 1 -.





- Remove Map Controlled Engine Cooling Thermostat ( F265) - arrows -.

Installing

Installation is in reverse order of removal, note the following:

• Replace O-ring.

- Clean and/or smooth O-ring sealing surface.

- Moisten new O-ring with coolant G12+.

- Install accessory assembly bracket. Refer to => [ Accessory Bracket ] Service and Repair

- Fill with coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Install generator.

- Install A/C compressor.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt

- Connect battery. Necessary measures. Refer to =>
Starting and Charging Starting and Charging

Tightening Specifications