Removal and Replacement

Cooling System Overview

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

• When the engine is warm the cooling system is under pressure. If necessary release pressure before commencing repair work.

• Secure all hose connections using hose clamps appropriate for the model. Refer to the electronic parts catalog ETKA.

• Hose clip pliers (V.A.G 1921) or spring type clip pliers (VAS 5024 A) are recommended for installing spring type clamps.

• Always replace gaskets and seals.

• Arrows on coolant pipes and coolant hoses must line up across from each other.






1 Bolt

• 40 Nm

2 Bolt

• 30 Nm

3 Coolant Pipe

4 Connecting Hose

5 O-ring

• Replace

6 Connecting Piece

7 Bolt

• 10 Nm

8 Retaining Clip

9 O-ring

• Replace

10 Engine Coolant Temperature Sensor (G62)

11 Connecting Hose

12 Connecting Piece

13 Connecting Hose

14 Connecting Hose

15 Connecting Hose

16 Coolant Pipe

17 Bolt

• 5 Nm

18 Connecting Hose

19 Coolant Pipe

20 Bolt

• 5 Nm

21 Coolant Distribution Housing

• With coolant thermostat

• Starts to open 87 °C (188.60 °F)

22 Bolt

• 15 Nm

23 Coolant Pump

• Removing and installing, refer to => [ Coolant Pump ] Service and Repair

24 Bolt

• 15 Nm