Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Components of cooling system, engine side
1 - Coolant pipe
- Secured to exhaust gas manifold together with heat shield
2 - 10 Nm
3 - To heat exchanger
- Coolant hose connection diagram → Coolant hose connection diagram
4 - From heat exchanger
- Coolant hose connection diagram → Coolant hose connection diagram
5 - Throttle valve control module J338
- Heated by coolant
- Removing and installing: → 24 MULTIPORT FUEL INJECTION (MFI)
6 - Cable guide
- For coolant hoses and wiring harness
7 - 8 Nm
8 - Upper coolant hose
- To top off radiator
- Check for secure seating
- Coolant hose connection diagram → Coolant hose connection diagram
9 - Bracket
- For wiring harness
10 - Lower coolant hose
- From bottom of radiator
- Check for secure seating
- Coolant hose connection diagram → Coolant hose connection diagram
11 - To cylinder block
- Coolant hose connection diagram → Coolant hose connection diagram
12 - After-Run Coolant pump V51
- Secured to cylinder block by a bracket
- Checking → After-Run Coolant pump V51 , checking
13 - Oil cooler
- Disassembling and assembling → Oil filter housing, disassembling and assembling , Disassembling and assembling oil filter housing
14 - O-ring
- Replace
15 - From cylinder block
- Coolant hose connection diagram → Coolant hose connection diagram
16 - Coolant pipe
17 - Sealing plug, 2 Nm
18 - Coolant pump
- Observe installation position
- Check for ease of movement
- If damaged or leaking replace complete
- Removing and installing → Coolant pump, removing and installing
19 - 20 Nm
20 - Belt pulley
- For coolant pump
- Removing and installing ribbed belt → Ribbed belt, removing and installing
- Removing and installing → Coolant pump, removing and installing , Removing and installing coolant pump
21 - 20 Nm
- Use Water pump wrench VAG1590/ to loosen and tighten → Coolant pump, removing and installing , Removing and installing coolant pump
22 - 25 Nm
23 - Expansion tank
- Perform leak test on cooling system with cooling system tester VAG 1274 and adapter VAG 1274/8
- Test pressure: 1.4...1.6 bar
- Observe markings → Cooling system, draining and filling , Draining and filling cooling system
24 - Seal
- Replace if damaged
25 - Sealing cap
- Check with cooling system tester VAG 1274 and adapter VAG 1274/9
- Pressure relief valve must open at a pressure of 1.4...1.6 bar
26 - Seal
- Replace
27 - Thermostat housing
- Disassembling and assembling → Coolant thermostat housing, disassembling and assembling
NO RELATED
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.