Contents: Petrol models 3.6 l ⬇ Petrol models 1.4 l ⬇ Petrol models 1.8 and 2.0 l ⬇ Diesel models 2.0 l (cFFB, CFGB,…⬇
Petrol models 3.6 l
1. The installation details of the water pump and other parts of the engine cooling system are shown in the accompanying illustration.
4.1 Engine cooling system parts
1 To the top of the expansion tank
2 To the rear coolant pipe
3 Nut connecting the rear side of the intake manifold support, 20 Nm
4 From the heater radiator
6 Coolant pipe, installed transversely from above
7, 10, 14, 35 Bolt, 10 Nm
8 From the DSG fluid radiator
9 Coolant pipe, installed transversely from below
11 Sensor ECT "G62"
12, 28 Sealing ring, subject to replacement
13 Retainer
15 To the top of the radiator
16 To additional radiator
17 From additional radiator
18 From the bottom of the radiator
19 Non-return valve
20 Coolant pipe, installed transversely in front
21 Bolt, 25 Nm
22 To the DSG fluid radiator
23 Coolant circulation pump "V55", is mounted on the bracket of auxiliary units with a force of 8 Nm
24, 29 Bolt, 8 Nm
25 Thermostat starts to open at 80°C
26 Coolant pipe with thermostat housing
27 From the bottom of the expansion tank
30 Coolant pump pulley
31 Bolt, 20 Nm
32 Coolant pump, with sealing ring glued on
33 Gasket, subject to replacement
34 Connection
2. Remove the sound insulation under the engine compartment (see Chapter 11) and unscrew the bolts (1-3 in Illustration 5.11 Chapter 2) swinging support.
3. Drain the coolant (see section 2).
4. Remove the accessory drive belt (see Chapter 2).
5. Remove the front bonnet bumpers from the top sides of both front fenders. Insert the T10311 plates on the right (And in illustration 5.47 Chapter 2) and left (B) sides in the direction of the arrows along the stop so that the arrows "R" and "L" on the plates point to the rear. These plates are needed to avoid damaging the wings.
6. Install the MP9-200 support with the MP9-200/3 and MP9-200/18 adapters (see illustration 5.48 Chapter 2). The heel of the support should rest against the buffers (1) and be located on top of the side beam (2). Evenly unload the power unit supports by rotating both spindles.
7. Loosen the bolts (arrows in illustration 5.28a) fastenings of the right engine bracket and lower the power unit on the MP9-200/18 spindles only enough to allow the coolant pump to be removed.
8. Holding the coolant pump pulley, unscrew the pulley fastener and remove it.
9. Remove the bolts (1 on the accompanying illustration) and remove the coolant pump (2).
4.9 Coolant pump fastening
10. Installation is carried out in the reverse order. Before installing the pump, moisten its sealing ring with coolant.
Petrol models 1.4 l
11. The installation details of the coolant pump and the coolant circulation pump are shown in the accompanying illustration.
4.11 Installation details of the coolant pump and thermostat for 1.4 l petrol engines
1 Coolant hose
2 Bolts, 8 Nm
3 Coolant circulation pump "V50"
4 Coolant hose
5 Support
6 Coolant pump, with built-in gasket
7 Bolt, 9 Nm
8, 10 Bolt, 20 Nm
9 Coolant pump pulley
12. Prepare the VAG1590 or MP1-308 key and bore the corners of its triangle to size (and in the accompanying illustrations) not less than 1 mm.
4.12 Refinement of the MP1-308 device
13. Remove the accessory drive belt (see Chapter 2).
14. Remove the bolts (see accompanying illustration) and remove the holder from the camshaft housing. Note: This holder serves as transport protection for the engine until the first installation and does not need to be reinstalled.
4.14 Removing the holder
15. Holding the coolant pump pulley from turning with the VAG1590 or MP1-308 key, unscrew the three bolts and remove the pulley (see accompanying illustration).
Note: When installing, tighten the bolts to 20 Nm.
4.15 Removing the coolant pump pulley
16. If necessary, after removing the pulley, you can remove the coolant pump. To do this, drain the coolant from the engine cooling system (see Section 2), unscrew the bolts (arrows in the accompanying illustration) and remove the coolant pump.
4.16 Removing the coolant pump
17. Installation is carried out in reverse order.
Petrol models 1.8 and 2.0 l
18. Details of the installation of the coolant pump and its components are shown in the accompanying illustration.
4.18 Installation details of the coolant pump and thermostat for 1.8 and 2.0 l petrol models
1, 5, 21 Sealing ring, subject to replacement
2 Connection
3 Retainer
4 Sensor ECT "G62"
19. Remove the small coolant pipe (see section 7).
20. Release the coolant hose (2 on the accompanying illustration) and the wiring harness (1). Unscrew the bolt (arrow) and remove the bracket.
4.20 Coolant hose and wiring bracket
21. Unscrew the bolt (2 in illustration 23.26 Chapter 2) on the bracket of the coolant circulation pump "V51".
22. Disconnect the coolant hoses (see accompanying illustration) and put them aside.
4.22 Coolant hoses
23. Remove the right front wheel arch liner (see Chapter 11).
24. Remove the bolts (arrows in illustration 25.4 Chapter 2), lift the clamps (1 and 2) and remove the air pressure tube.
25. Loosen the oil separator fasteners and close the resulting hole to prevent dirt from getting in. Then unscrew the bolts (see accompanying illustration) and remove the coolant pump drive belt cover located behind the oil separator.
4.25 Fastening the coolant pump drive belt cover
26. Using the VAG1331 key and the T10360 insert, loosen the bolt (with left-hand thread) gear wheel fastenings (1 on the accompanying illustration) coolant pump, while holding the toothed wheel from above to prevent it from turning. Remove the toothed wheel and the belt (2) of the coolant pump drive.
4.26 Removing the coolant pump drive belt
27. If necessary, after removing the coolant pump belt, replace the coolant pump seal.
Note: The inscription "Air side" or "Outside" on the seal must be read from the top.
28. If necessary, after removing the coolant pump belt, remove the coolant pump itself, as described below.
29. Disconnect the connector (1 on the accompanying illustration), unscrew the bolts (arrows) and remove the throttle module "J338".
4.29 Connector and fastening of the throttle module
30. Disconnect the connector (1 on the accompanying illustration) eCT sensor.
4.30 Removing the ECT sensor
31. Remove the bolts (1-5 on the accompanying illustration), remove the coolant pump from the centering pins and pull it out of the oil cooler.
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4.31 Coolant pump mounting bolts
32. Installation is carried out in the reverse order. Use a new coolant pump sprocket mounting bolt, as well as new gaskets and sealing rings. Before installing the coolant pump, make sure that both of its centering pins are inserted into the cylinder block and insert the connection (2 in illustration 4.18) into the oil cooler. Tighten the oil pump mounting bolts in the sequence (1-5 in illustration 4.31). When installing a new coolant pump, remove the protective cap (arrow) from it.
Diesel models 2.0 l (cFFB, CFGB, CLJA engines)
33. The details of the installation of the coolant pump and the 4/2-way valve with thermostat are shown in the accompanying illustration. To remove the coolant pump, it is necessary to remove the timing belt (see Chapter 2). Before installing the pump, moisten its new sealing ring with coolant.
4.33 Installation details of the coolant pump and 4/2-way valve with thermostat
1 Coolant pump
2, 6 Bolt, 15 Nm
3, 4 Sealing ring, subject to replacement
5 4/2-way valve combined with thermostat (separate replacement is not provided)