Engine Component Layout And Replacement

Cooling System Components, Removing And Installing

NOTE:
When the engine is warm the cooling system is under pressure. Be sure to release pressure before starting the repair.

Hoses are secured with spring-type clamps. In case of repair replace only with spring-type clamps.

Use commercially available pliers such as Hazet 798-5 when installing spring-type clamps.

When installing coolant-hoses they must not be stressed or contact other components (note markings on coolant connection and hose).

Draining and filling coolant and coolant mixture ratios refer to "Cooling System Draining and Filling". Cooling System Draining and Filling

Check for coolant leaks using VAG 1274 and 1274/3

Cooling System Engine Component Layout





1 - 25 Nm (18 ft lb)
- Use wrench VAG 1590 to loosen
- Modify wrench VAG 1590 see Fig. 1 below.

2 - Pulley
- For engine coolant pump

3 - 20 Nm (15 ft lb)

4 - Engine coolant pump
- Check shaft for ease of movement
- Removing and installing refer to :"Engine Coolant Pump, Removing and Installing". Service and Repair

5 - O-ring
- Replace.

6 - Throttle body

7 - From cylinder head

. 8 - After-run coolant pump (V51)
- Checking refer to "Coolant After-Run System, Checking". Service and Repair
- Mounted with bracket to camshaft sprocket cover.

9 - Connector

10 - Retaining clip
- Must be seated correctly

11 - Engine Coolant Temperature (ECT) Sensor (G62)
- Color black
- Only for Climatronic (Automatic Climate Control)
- 2-pin connector

12 - From heat exchanger

13 - To heat exchanger

14 - Cap
- Check with VAG 1274 and 1274/4
- Test pressure: 1.3 to 1.5 bar

15 - Cover

16 - 10 Nm (7 ft lb)

17 - Expansion tank

18 - Upper coolant hose
- To top of radiator refer to item 20 in "Body Component Layout And Replacement". Body Component Layout And Replacement

19 - Lower coolant hose
- To bottom of radiator refer to item 16 in "Body Component Layout And Replacement". Body Component Layout And Replacement

20 - Automatic transmission fluid (ATF) cooler
- Only for vehicles with automatic transmission

21 - Thermostat housing
- Disassembling and assembling refer to "Thermostat Housing, Disassembling and Assembling".

22 - Coolant hose

23 - Oil cooler

24 - To cylinder block

25 - Drain plug 10 Nm (7 ft lb)
- Draining and filling with coolant refer to "Cooling System Draining and Filling". Cooling System Draining and Filling

Wrench VAG 159O For Coolant Pump, Modifying

Fig. 1:

- Because the mounting bolts for the coolant pump were changed, enlarge wrench by -a- = 1 mm, using a file.