Volkswagen Cars 2000-05

Removal & Installation

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CAUTION
NEVER open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.


NOTE
Apply an anti-seizing compound to the thermostat housing fastener threads before reinstalling them.

1.9L Diesel Engine




NOTE
This procedure requires the following special tools, or their equivalents:



T10007 Refractometer
 
V.A.G 1306 Drip tray
 
V.A.G 1331 Torque wrench (5 to 50 Nm)
 
VAS 5024 Assembly tool for spring-type clips
 


NOTE
Whenever you remove the thermostat, always replace all seals and gaskets.

  1. Drain the coolant into a suitable container.
  2.  
  3. Disconnect the coolant hose from the connecting flange.
  4.  
  5. Unfasten the mounting bolts from the connecting union, then remove the connecting union with the thermostat.
  6.  
  7. Turn thermostat 1 / 4 -turn (90°) to left and remove it from the connecting union.

    Click image to see an enlarged view

    Fig. Exploded view of the mounting bolts (1), connecting union (2), O-ring (3) and thermostat (4)-1.9L (BEW) diesel engine



    Click image to see an enlarged view

    Fig. Exploded view of the mounting bolts (1), connecting union (2), O-ring (3) and thermostat (4)-1.9L (ALH) diesel engine

  8.  

To install:

  1. Lubricate a O-ring with clean engine coolant.
  2.  
  3. Insert the thermostat into connecting union, then turn 1 / 4 -turn (90°) to the right.
    NOTE
    The brace on the thermostat must be almost vertical.

  4.  
  5. Install the union with the thermostat into engine block.
  6.  
  7. Tighten the union mounting bolts to 11 ft. lbs. (15 Nm).
  8.  
  9. Connect the coolant hose.
  10.  
  11. Fill the engine with the proper type and amount of coolant.
  12.  

2.0L (Aba) Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Coolant
     
    Thermostat housing from under the water pump housing.
     
    Thermostat. Remove and discard the O-ring.
     

  4.  

To install:

  1. Position a new O-ring, then install the thermostat.
  2.  
  3. Install the thermostat and housing. Bolts: 84 inch lbs. (10 Nm).
  4.  
  5. Fill the cooling system with the proper type and amount of coolant.

    Click image to see an enlarged view

    Fig. Water pump and thermostat housing-2.0L (ABA) engine

  6.  

2.0L (Bhw) Engine




NOTE
This procedure requires the following special tools, or their equivalents:



T10007 Refractometer
 
V.A.G 1306 Drip tray
 
V.A.G 1331 Torque wrench (5 to 50 Nm)
 
VAS 5024 Assembly tool for spring-type clips
 


NOTE
Whenever you remove the thermostat, always replace all seals and gaskets.

  1. Drain the coolant into a suitable container.
  2.  
  3. Disconnect the coolant hose from housing.
  4.  
  5. Unscrew the bolts from the thermostat housing and remove it with the thermostat.
  6.  
  7. Turn coolant thermostat 1 / 4 (90°) to the left, then remove it from the housing.

    Click image to see an enlarged view

    Fig. Exploded view of the bolts (2), thermostat housing (2), O-ring (3) and thermostat (4)

  8.  

To install:

  1. Lubricate a O-ring with clean engine coolant.
  2.  
  3. Insert the thermostat into connecting piece, then turn 1 / 4 -turn (90°) to the right.
    NOTE
    The clip of the thermostat must be positioned at about right angle.

  4.  
  5. Install the housing with the thermostat into engine block.
  6.  
  7. Tighten the connecting piece mounting bolts to 11 ft. lbs. (15 Nm).
  8.  
  9. Connect the coolant hose.
  10.  
  11. Fill the engine with the proper type and amount of coolant.
  12.  

2.0L Engines, Except 2.0L (Aba And Bhw Engines)




NOTE
This procedure requires the following special tools, or their equivalents:



T10007 Refractometer
 
V.A.G 1306 Drip tray
 
V.A.G 1331 Torque wrench (5 to 50 Nm)
 
VAS 5024 Assembly tool for spring-type clips
 


NOTE
Whenever you remove the thermostat, always replace all seals and gaskets.

  1. Drain the coolant to a level below the thermostat.
  2.  
  3. Disconnect the coolant hose from the union.
  4.  
  5. Unfasten the mounting bolts from the union, then remove union with the thermostat.
  6.  
  7. Remove and discard the O-ring. Thoroughly clean the gasket making surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the thermostat (1), O-ring (2), union (3) and bolts (4)

  8.  

To install:

  1. Lubricate a O-ring with clean engine coolant.
  2.  
  3. Install the union with the thermostat into engine block.
    NOTE
    The brace on the thermostat must be almost vertical.

  4.  
  5. Tighten the union mounting bolts to 11 ft. lbs. (15 Nm).
  6.  
  7. Connect the coolant hose.
  8.  
  9. Fill the engine with the proper type and amount of coolant.
  10.  

2.8L (Afp) Engine




NOTE
This procedure requires the following special tools, or their equivalents:



T10007 Refractometer
 
V.A.G 1306 Drip tray
 
V.A.G 1331 Torque wrench (5 to 50 Nm)
 
VAS 5024 Assembly tool for spring-type clips
 


NOTE
Whenever you remove the thermostat, always replace all seals and gaskets.

  1. Drain the coolant to a level below the thermostat.
  2.  
  3. Disconnect the coolant hose(s) from the thermostat housing.
  4.  
  5. Unfasten the mounting bolts from the thermostat housing, then remove the housing with the thermostat.
  6.  
  7. Remove and discard the O-ring. Thoroughly clean the gasket making surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the thermostat and related components-2.8L (AFP) engine



    Click image to see an enlarged view

    Fig. Exploded view of the thermostat and related components-2.8L (BDF) engine

  8.  

To install:

  1. Lubricate a new O-ring with clean engine coolant.
  2.  
  3. Install the union with the thermostat into engine block.
    NOTE
    The brace on the thermostat must be almost vertical.

  4.  
  5. Tighten the union mounting bolts to 7 ft. lbs. (10 Nm).
  6.  
  7. Connect the coolant hose(s).
  8.  
  9. Fill the engine with the proper type and amount of coolant.
  10.  

2.8L (Atq) Engine




NOTE
This procedure requires the following special tools, or their equivalents:



T10007 Refractometer
 
V.A.G 1306 Drip tray
 
V.A.G 1331 Torque wrench (5 to 50 Nm)
 
VAS 5024 Assembly tool for spring-type clips
 


NOTE
Whenever you remove the thermostat, always replace all seals and gaskets.


NOTE
Cover the belt with a rag or cloth before remove the coolant regulator.

  1. Set the lock carrier in the service position, as outlined in the Engine Mechanical Section.
  2.  
  3. Drain the coolant to a level below the thermostat.
  4.  
  5. Perform the timing belt procedure as outlined in this section, except note the following:
    1. Remove vibration damper/belt pulley.
    2.  
    3. Remove toothed belt guard/belt pulley.
    4.  
    5. Remove bracket for viscous fan clutch.
    6.  
    7. Unfasten the connecting piece bolts, then remove the connecting piece.
    8.  
    9. Remove the thermostat.
    10.  

  6.  
  7. Remove and discard the O-ring.

    Click image to see an enlarged view

    Fig. Exploded view of the connecting piece bolts (1), connecting piece (2), O-ring (3) and thermostat (4)-2.8L (ATQ) engines

  8.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following:
    1. Lubricate a new O-ring with engine coolant.
    2.  
    3. When you insert the thermostat into the cylinder block, the bleeder valve for the thermostat (arrow) must be positioned at the top.

      Click image to see an enlarged view

      Fig. When you insert the thermostat into the cylinder block, the bleeder valve for the thermostat (arrow) must be positioned at the top

    4.  
    5. Tighten the connecting piece mounting bolts to 7 ft. lbs. (10 Nm).
    6.  
    7. Install and tension the timing belt, as outlined in this section.
    8.  
    9. Fill system with coolant.
    10.  

  2.  

2.8L Engine



The thermostat is located in the engine block just to the side of the water pump underneath the housing where the upper radiator hose is attached.

  1. Remove the lower engine shield.
  2.  
  3. Place a large drain pan under the vehicle to collect the coolant.
  4.  
  5. Remove the radiator cap and drain the cooling system into a suitable container.
  6.  
  7. Place a large drain pan under the engine block drain located at the bottom of the engine near the vicinity of the flywheel and the oil pan.
  8.  
  9. Drain the engine block coolant into a suitable container.
  10.  
  11. Place the (hood) lock carrier in the 'service position'. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  12.  
  13. Remove the accessory drive belt. For additional information, please refer to the following topic(s): General Information And Maintenance, Routing Maintenance And Tune-Up.
  14.  
  15. If installed, remove the upper front engine cover.
  16.  
  17. Remove the toothed camshaft drive belt from the right side cylinder head to allow enough access to remove the thermostat housing. Cover and protect the drive belt from residual coolant.
  18.  
  19. Remove the mounting fasteners; remove the housing, then the thermostat.
  20.  



Click image to see an enlarged view

Fig. An exploded view of the water pump, thermostat housing and thermostat-2.8L V6 engines



Click image to see an enlarged view

Fig. Lubricate the O-ring with coolant and make sure the thermostat is installed with the bleeder facing up-2.8L V6 engines

To install:


WARNING
The thermostat vent valve must be installed facing up otherwise the cooling system may develop air pockets and allow the engine to overheat.

  1. Using new O-ring, install the thermostat making sure the vent valve is installed facing up.
  2.  
  3. Install the thermostat housing and torque the housing the bolts to 88 inch lbs. (10 Nm).
  4.  
  5. Inspect the camshaft drive belt for wear and damage and replace if necessary. If contaminated with fluids or lubricants, it should be replaced. For additional information, please refer to the following topic(s): General Information And Maintenance, Routine Maintenance And Tune-Up, Engine And Engine Overhaul, Timing Belt And Sprockets.
  6.  
  7. Installation is in reverse order of removal noting the following:
  8.  
  9. Top off cooling system with the recommended fluid and concentration. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  10.  

2.8L VR6 Engine





Click image to see an enlarged view

Fig. Exploded view of a VR6 thermostat housing

The thermostat is mounted in the housing and located on the rear of the cylinder head.

  1. Drain the engine coolant into a suitable container.
  2.  
  3. Remove the mounting bolts from the flange.
  4.  
  5. Remove the flange and the thermostat.
  6.  

To install:

  1. Install the thermostat with a new O-ring.
  2.  
  3. Install the thermostat housing.
  4.  
  5. Install and tighten the fasteners.
  6.  
  7. Top off cooling system with the recommended fluid and concentration. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  8.  

4-Cylinder





Click image to see an enlarged view

Fig. Remove the housing bolts



Click image to see an enlarged view

Fig. Once all bolts have been remove, pull the thermostat housing away from the bottom of the water pump unit



Click image to see an enlarged view

Fig. Note the position of the thermostat and gasket


NOTE
On some models the thermostat is in the bottom of the water pump housing.

  1. Place a large drain pan under the vehicle to collect the coolant.
  2.  
  3. Remove the radiator cap and drain the cooling system.
  4.  
  5. Loosen one bolt at a time until coolant begins to flow.
  6.  
  7. Remove both bolts and remove the thermostat.
  8.  

To install:

  1. Install the new O-ring.
  2.  
  3. Torque the housing the bolts to 7 ft. lbs. (10 Nm).
  4.  

The thermostat is located in the bottom of the water pump housing.

  1. If equipped, remove the lower engine shield.
  2.  
  3. Place a large drain pan under the vehicle to collect the coolant.
  4.  
  5. Remove the radiator cap and drain the cooling system into a suitable container.
  6.  
  7. On 1.8L engines, remove the water pump housing drain plug.
  8.  
  9. Loosen one bolt at a time until coolant begins to flow.
  10.  
  11. Remove both bolts and remove the thermostat.
  12.  



Click image to see an enlarged view

Fig. Remove the housing bolts



Click image to see an enlarged view

Fig. Once the bolts have been removed, pull the thermostat housing away from the bottom of the water pump unit



Click image to see an enlarged view

Fig. Note the position of the thermostat and gasket



Click image to see an enlarged view

Fig. The 1.8L engines have a water pump drain plug near the thermostat housing



Click image to see an enlarged view

Fig. An exploded view of the water pump, pump housing and thermostat-1.8L engine illustrated



Click image to see an enlarged view

Fig. The 1.8L water pump, drain and thermostat housing

To install:

  1. Install the thermostat using new O-ring.
  2.  
  3. If removed, install the water pump drain plug with a new O-ring and tighten to 22 ft. lbs. (30 Nm).
  4.  
  5. Torque the housing the bolts to 88 inch lbs. (10 Nm).
  6.  
  7. Top off cooling system with the recommended fluid and concentration. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  8.  

VR-6





Click image to see an enlarged view

Fig. Exploded view of a VR6 thermostat housing

On 6 cylinder models, the thermostat is mounted in the housing. The thermostat housing is located on the rear of the cylinder head.

  1. Drain the engine coolant.
  2.  
  3. Remove the mounting bolts from the flange.
  4.  
  5. Remove the flange and the thermostat.
  6.  

To install:

  1. Install the new thermostat and O-ring.
  2.  
  3. Install the thermostat housing.
  4.  
  5. Install and tighten the fasteners.
  6.  
  7. Fill the cooling system with approved antifreeze.
  8.  

 
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