4/2-Way Valve with Coolant Thermostat

4/2-Way Valve with Coolant Thermostat

Special tools, testers and auxiliary items required

• T Bar and Socket 10 mm hinged socket (3185)

• Refractometer (T10007)

• Hex Ball Socket (T10058)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Drip Tray for VAS 6100 (VAS 6208)

• Hose Clip Pliers (VAS 6340)

• Pry Lever - Rmv Outside Mirror (80-200)

Removing

The coolant system is under pressure when the engine is warm.

Risk of scalding due to hot steam and hot coolant.

Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

• Hoses are secured with spring-type clips. In cases of repair only use spring-type clips.

• Hose clip pliers (VAS 6340) are recommended for installing spring-type clamps.

• When installing coolant hoses, make sure they are free of stress and do not come into contact with other components (observe markings on coolant connections and hoses).

• Always replace the gaskets and seals.

- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Remove the generator.

- Remove the charge air cooler. Refer to => [ Charge Air Cooler ] Charge Air Cooler.

- Remove the nut - arrow A - for the coolant pipe - 1 -.






- Loosen the bolts - arrows - and remove the support - 1 -.






- Remove the bolt - 1 -.






- Remove the clip - 2 - using the pry lever - rmv outside mirror (80-200).

- Pull the oil dipstick tube out of the cylinder block and move it to the side.

- Remove the air filter housing with the mass air flow sensor and connecting pipe. Refer to => [ Air Filter Housing ] Air Filter Housing.

- Remove the battery.

- Remove the battery tray bolts - arrows - and tray - 1 -.






- Press the release buttons and remove the crankshaft housing ventilation hose - 1 - from the cylinder head cover.






- Disconnect the connector and remove it from the crankcase ventilation hose - 1 -.

- Free up the vacuum hoses - arrows - from the air guide pipe.

- Remove the bolt - 2 - and tilt the air guide pipe with the intake tube backward and remove from the turbocharger.

- Remove the bolt - arrow -.






- Unclip the preheating pipe - 1 - and remove it from the bracket.

with a Direct Shift Gearbox (DSG(R))






- Loosen the hose clamps - arrows - and remove the coolant hoses from the transmission fluid cooler.

Continuation for All

- Remove the bolt - arrow -.






- Free up the electrical wires and the hoses on the left air guide pipe - 1 - using the pry lever - rmv outside mirror (80-200).

- Loosen the hose clamp - 2 - and remove the air guide pipe - 1 -.

- Disconnect the coolant hoses by loosening the hose clamp - 1 -.






- Disconnect the connector - 1 - for the camshaft position sensor from out of the mount.






- Remove the bolts - arrows -.

- Pull the coolant pipe - A - with the wire bracket out of the connection for the 4/2-way valve - 1 -.






- Push the coolant pipe aside, do not remove it.

- Disconnect the coolant hoses - B through D - from the connection.






- Disengage and disconnect the connector - 2 -.

- Remove the 4/2-way valve bolts - arrows -.

- Remove the 4/2-way valve - 1 - from the cylinder block.

Installing

Install in reverse order of removal. When doing this note the following:

• Always replace the gaskets and seals.

- Fill the coolant. Refer to => [ Draining and Filling ] Procedures.

Tightening Specifications