Volkswagen Eurovan 2000-03

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Remove noise insulation pan, as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Exploded view of the sound dampening material (1), clip (2) and noise insulation pan (3)

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  5. Drain the coolant to a level below the thermostat.
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  7. Remove the accessory drive belt, as outlined in this section.
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  9. Remove any other component necessary for access to the thermostat.
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  11. Unfasten the hoses and retaining bolts, then remove the thermostat housing.
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  13. Remove the thermostat, then disassemble the housing, as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Exploded view of the O-ring (1), retaining clip (2), thermostat housing (3), bolts (4), thermostat (5), connecting piece (6), seal (7), ECT sensor (8), and sealing plug (9)

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To install:

  1. Installation is the reverse of the removal procedure. Use new gaskets and tighten the thermostat housing bolts to 7 ft. lbs. (10 Nm).
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  3. Fill the cooling system as follows and noting the following items:
    WARNING
    If the fluid in expansion tank is brown, the G12 has been mixed with other coolant. If this is the case, the coolant MUST be replaced.

    1. Only use coolant additive G12 (according to TL VW 774 D). The G-12 is red in color. Never mix G12 with any other coolant additive! Refer to the accompanying table for recommended coolant mixture ratios.
      NOTE
      The T10007 refractometer is recommended for determining frost protection density.

    2.  
    3. If the radiator, heater core, cylinder head or cylinder head gasket is replaced, completely replace the engine coolant.

      Click image to see an enlarged view

      Fig. Recommended coolant mixture ratios

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    5. Fill coolant to the MAX line on the expansion tank.

      Click image to see an enlarged view

      Fig. Fill the coolant to the MAX mark on the expansion tank

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    7. Close expansion tank.
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    9. Switch A/C system and heater off.
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    11. Start engine and maintain an engine speed of about 2000 RPM for approx. 3 minutes.
    12.  
    13. Allow engine to idle until lower coolant hose at radiator is hot.
    14.  
    15. Check coolant level and top-off with coolant if necessary. With engine at operating temperature, coolant level must be at MAX. marking, with engine cold, it must be between MIN. and MAX. marking.
    16.  

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