Volkswagen Cars 2000-05

Removal & Installation

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Fig. Removing the hose clamp from the lower radiator hose



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Fig. Remove the clamp from the hose and then slide the hose off



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Fig. Hoses can bake onto a fitting. Use a suitable cotter pin removal tool with a blunt end and spray the connection with a suitable penetrating lubricant



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Fig. Carefully work the cotter pin removal tool around, between the fitting and the hose



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Fig. With care, patience and persistence, the hose can be removed without damaging the fitting or the hose

  1. Allow the engine to cool below 100°F (37°C).
  2.  
  3. Remove the radiator pressure cap.
  4.  


CAUTION
NEVER remove the pressure cap while the engine is running, or personal injury from scalding hot coolant or steam may result. If possible, wait until the engine has cooled to remove the pressure cap. If this is not possible, wrap a thick cloth around the pressure cap and turn it slowly to the stop. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, use the cloth to turn and remove the cap.

  1. On models equipped with a lower engine cover, remove the cover.
  2.  
  3. Position a clean container under the radiator and/or engine draincock or plug, then open the drain and allow the cooling system to drain to an appropriate level. For some upper hoses, only a little coolant must be drained. To remove hoses positioned lower on the engine, such as a lower radiator hose, the entire cooling system must be emptied.
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a resealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Loosen the hose clamps at each end of the hose requiring replacement. Clamps are usually either of the spring tension type (which require pliers to squeeze the tabs and loosen) or of the screw tension type (which require screw or hex drivers to loosen). Pull the clamps back on the hose away from the connection.
  2.  
  3. Twist, pull and slide the hose off the fitting, taking care not to damage the neck of the component from which the hose is being removed.
  4.  


NOTE
If the hose is stuck at the connection, Do NOT try to insert a screwdriver or other sharp tool under the hose end in an effort to free it, as the connection and/or hose may become damaged. Heater connections especially may be easily damaged by such a procedure. If the hose is to be replaced, use a single-edged razor blade to make a slice along the portion of the hose that is stuck on the connection, perpendicular to the end of the hose. Do NOT cut deep so as to prevent damaging the connection. The hose can then be peeled from the connection and discarded.

  1. Clean both hose mounting connections. Inspect the condition of the hose clamps and replace them, if necessary.
  2.  

To install:

  1. Dip the ends of the new hose into clean engine coolant to ease installation.
  2.  
  3. Slide the clamps over the replacement hose, then slide the hose ends over the connections into position.
  4.  
  5. Position and secure the clamps at least 1 / 4 in. (6.35mm) from the ends of the hose. Make sure they are located beyond the raised bead of the connector.
  6.  
  7. Close the radiator or engine drains and properly refill the cooling system with the clean drained engine coolant or a suitable mixture of coolant and water.
  8.  


NOTE
The engines covered in this manual use a special type of coolant in later model vehicles. It is recommended that the specified type of coolant only be used in the engine's cooling system, to prevent premature corrosion and deterioration of cooling system components. Refer to the Fluids And Lubricants heading within this section for more information.

  1. If available, install a pressure tester and check for leaks. If a pressure tester is not available, run the engine until normal operating temperature is reached (allowing the system to naturally pressurize), then check for leaks.
  2.  


CAUTION
If you are checking for leaks with the system at normal operating temperature, BE EXTREMELY CAREFUL not to touch any moving or hot engine parts. Once temperature has been reached, shut the engine OFF, and check for leaks around the hose fittings and connections that were removed earlier.



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Fig. Removing the hose clamp from the lower radiator hose



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Fig. Remove the clamp from the hose and then slide the hose off

  1. Remove the radiator pressure cap.
  2.  


CAUTION
Never remove the pressure cap while the engine is running, or personal injury from scalding hot coolant or steam may result. If possible, wait until the engine has cooled to remove the pressure cap. If this is not possible, wrap a thick cloth around the pressure cap and turn it slowly to the stop. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, use the cloth to turn and remove the cap.

  1. Position a clean container under the radiator and/or engine draincock or plug, then open the drain and allow the cooling system to drain to an appropriate level. For some upper hoses, only a little coolant must be drained. To remove hoses positioned lower on the engine, such as a lower radiator hose, the entire cooling system must be emptied.
  2.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a resealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Loosen the hose clamps at each end of the hose requiring replacement. Clamps are usually either of the spring tension type (which require pliers to squeeze the tabs and loosen) or of the screw tension type (which require screw or hex drivers to loosen). Pull the clamps back on the hose away from the connection.
  2.  
  3. Twist, pull and slide the hose off the fitting, taking care not to damage the neck of the component from which the hose is being removed.
  4.  


NOTE
If the hose is stuck at the connection, do not try to insert a screwdriver or other sharp tool under the hose end in an effort to free it, as the connection and/or hose may become damaged. Heater connections especially may be easily damaged by such a procedure. If the hose is to be replaced, use a single-edged razor blade to make a slice along the portion of the hose which is stuck on the connection, perpendicular to the end of the hose. Do not cut deep so as to prevent damaging the connection. The hose can then be peeled from the connection and discarded.

  1. Clean both hose mounting connections. Inspect the condition of the hose clamps and replace them, if necessary.
  2.  

To install:

  1. Dip the ends of the new hose into clean engine coolant to ease installation.
  2.  
  3. Slide the clamps over the replacement hose, then slide the hose ends over the connections into position.
  4.  
  5. Position and secure the clamps at least 1 / 4 in. (6.35mm) from the ends of the hose. Make sure they are located beyond the raised bead of the connector.
  6.  
  7. Close the radiator or engine drains and properly refill the cooling system with the clean drained engine coolant or a suitable mixture of coolant and water.
  8.  


NOTE
Volkswagen uses a special type of coolant in later model vehicles. It is recommended that the specified type of coolant only be used in the engine's cooling system, to prevent premature corrosion and deterioration of cooling system components. Refer to the Fluids And Lubricants heading within this section for more information.

  1. If available, install a pressure tester and check for leaks. If a pressure tester is not available, run the engine until normal operating temperature is reached (allowing the system to naturally pressurize), then check for leaks.
  2.  


CAUTION
If you are checking for leaks with the system at normal operating temperature, BE EXTREMELY CAREFUL not to touch any moving or hot engine parts. Once temperature has been reached, shut the engine OFF, and check for leaks around the hose fittings and connections which were removed earlier.

4-Cylinder Engines





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Fig. Removing the thermostat from the bottom of the water pump



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Fig. View of the thermostat in the housing

On 4-cylinder engines, the most thorough way to drain the coolant from the engine is by removing the thermostat. The thermostat on all 4-cylinder engines is located at the bottom of the water pump housing. The lower radiator hose attaches directly to the thermostat cover/elbow.


CAUTION
Never attempt to drain the coolant from a hot engine. This is a messy job and there is no way to drain the coolant without getting it on your hands. Make sure the engine is thoroughly cooled before performing this procedure.

  1. Before raising the front of the vehicle, place the temperature control knob/slider to its warmest setting.
  2.  
  3. Raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Some vehicles have a splash shield underneath the vehicle that may obstruct access to the thermostat cover/elbow. Remove the shield if necessary.
  6.  
  7. Place a large drain pan (large enough to contain the entire cooling system contents) under the water pump. Make sure the drain pan is clean, since the coolant should be reused unless it is dirty, or it does not pass a hydrometer test.
  8.  
  9. Using a 10mm socket and ratchet, loosen (but do not remove) the thermostat cover/elbow bolts. Coolant will start to flow from the elbow, so make sure the drain pan is positioned properly.
  10.  
  11. When the coolant stops flowing, remove the thermostat cover/elbow bolts, and set the cover/elbow aside. It's not necessary to disconnect the lower radiator hose. When removing the cover/elbow bolts, hold the cover/elbow in place; then, slowly lower the cover/elbow and hose. The thermostat may stick in place; be careful when removing it, as residual coolant may still be in the engine.
  12.  
  13. Once the thermostat is remove, remove the coolant reservoir cap to drain the rest of the coolant.
  14.  

To install:

  1. Clean and dry the thermostat housing and the rubber O-ring. Examine the O-ring for cracks or damage and replace as necessary.
  2.  
  3. Install the thermostat into the water pump housing on the engine, then fit the O-ring into place.
  4.  
  5. Install the thermostat housing and tighten the bolts evenly. Torque the bolts to 87 inch lbs. (10 Nm). Do not over torque these bolts or the housing may break.
  6.  
  7. If equipped, install the splash shield.
  8.  
  9. Lower the vehicle from the jackstands. Make sure the car is level.
  10.  
  11. Loosen the upper radiator hose and begin filling the system (with the proper mixture of coolant and distilled water) through the coolant reservoir. Loosening the upper hose will allow the air to escape and speed the process.
  12.  
  13. When the system will not take any more coolant, tighten the hose and start the engine. Watch for leaks, and add more coolant as required. Don't run the engine too long with the reservoir cap removed or it will boil over.
  14.  

Vr6 Engines



On VR6 engines, a drain plug is installed in the coolant pipe, which runs between the coolant pump and the thermostat housing.

  1. Before raising the front of the vehicle, place the temperature control knob/slider to its warmest setting.
  2.  
  3. Raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Some vehicles have a splash shield underneath the vehicle that may obstruct access to the coolant pipe. Remove the shield if necessary to allow adequate access to the coolant pipe.
  6.  
  7. Place a large drain pan (large enough to contain the entire cooling system contents) under the drain plug. Make sure the drain pan is clean, since the coolant should be reused unless it is dirty, or it does not pass a hydrometer test.
  8.  
  9. Loosen (but do not remove) the coolant drain plug. Push against the drain plug while unscrewing it by hand. When the drain plug is free of the threads, quickly remove it from the coolant pipe, and allow the coolant to drain from the vehicle.
  10.  
  11. While the coolant is draining, remove the coolant reservoir cap; this will allow thorough draining of the system.
  12.  

To install:

  1. Using a new O-ring on the drain plug, install the drain plug into the coolant pipe. Tighten the drain plug to 89 inch lbs. (10 Nm).
  2.  
  3. If equipped, install the splash shield.
  4.  
  5. Lower the vehicle from the jackstands. Make sure the car is level.
  6.  
  7. Using either the drained coolant, or a fresh mixture of the proper type of coolant and distilled water, slowly fill the cooling system through the coolant reservoir. If possible, loosen the upper hose; this will allow the air to escape and speed the process.
  8.  
  9. When the system will not take any more coolant, tighten the hose (if loosened) and start the engine. Watch for leaks, and add more coolant as required. Don't run the engine too long with the reservoir cap removed or it will boil over.
  10.  

 
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