Contents: 1.2-/1.4-litre petrol engine, except…↓ Removal ↓ Installation ↓ Diesel engine 1.4-/1.9-I-PD-TDI ↓ 1.9L SDI diesel engine ↓
1.2-/1.4-litre petrol engine, except 1.4-litre FSI engine
1 - connecting pipe
2 - self-tapping screw
3 - sealing ring
4 - thermostat
5 - to the heat exchanger
6 - from the expansion tank
7 — thermostat housing
8 - from the heat exchanger
9 — coolant pipeline
10 - sealing ring
11 — coolant pump housing on the cylinder block
12 — clamp
13 — bolt, 10 Nm
14 - cork
15 - coolant temperature sensor
16 - clamps
17 - self-tapping screw
18 — holder
19 - to the top of the radiator
20 - from the bottom of the radiator
Removal
Drain the coolant, see previous chapter.
Unscrew 2 screws "2" and remove the connecting pipe "1" from the thermostat housing "7" together with the sealing ring "3".
Remove thermostat "4" from the housing.
Installation
The sealing ring must be replaced.
Clean the surfaces under the sealing ring.
Insert the thermostat into the housing.
Insert a new sealing ring and tighten the fastening screws to a torque of 9 Nm.
Fill with coolant, see previous chapter.
Diesel engine 1.4-/1.9-I-PD-TDI
The thermostat is located at the front of the cylinder block, next to the dipstick.
Removal
Drain the coolant, see previous chapter.
Diesel engine 1.4-I-PD-TDI: remove the alternator, see page 65.
Remove the coolant hose from the connecting pipe "2" at the cylinder block, for which first release and move the spring clamp onto the hose.
Unscrew the 2 bolts "1" securing the connecting pipe "2" to the cylinder block and remove the pipe together with the thermostat.
Turn thermostat "4" 90° (¼ turn) to the left and remove it from the connecting pipe.
Remove and replace sealing ring "3".
Installation
Moisten the new sealing ring "3" with coolant and insert it into the connecting pipe "2".
Insert thermostat "4" into the connecting pipe and turn it 90° (1/4 turn) to the right.
Note: The thermostat bracket should be positioned almost vertically.
Attach the connecting pipe assembly with the thermostat to the cylinder block and tighten the mounting bolts to a torque of 15 Nm.
Place the coolant hose on the branch pipe and secure it with a clamp.
Diesel engine 1.4-I-PD-TDI: install generator.
Fill with coolant.
Start the engine and let it idle until the thermostat valve opens — and the lower coolant hose becomes warm. Check the sealing of the connecting pipe and the connection point of the coolant hose for tightness.
1.9L SDI diesel engine
The thermostat is located in the coolant pipe at the front of the cylinder block, next to the oil filter housing.
Removal
Drain the coolant,m. the corresponding chapter above.
Remove the top engine cover.
Unscrew 2 bolts "1" securing connecting pipe "2" to the cylinder block, collect the leaked coolant. Put the connecting pipe together with the attached hose aside.
Turn thermostat "4" 90° (¼ turn) to the left and remove it from the connecting pipe.
Installation
Thoroughly clean the surfaces under the sealing ring "3".
Moisten the new sealing ring with coolant and insert it into the connecting pipe.
Insert thermostat "4" into the connecting pipe and turn it 90° (¼ turn) to the right. The thermostat bracket should be almost vertical in the installation position.
Attach the connecting pipe assembly with the thermostat to the cylinder block and tighten the mounting bolts to a torque of 15 Nm.
Fill with coolant, see the relevant chapter above.
Check the cooling system for leaks.
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