Removing and installing 4/2-way valve with thermostat

Special tools and workshop equipment required

• 10 mm jointed spanner - 3185-
• Refractometer - T10007-
• Multi-point bit - T10058-
• Torque wrench - V.A.G 1331/-
• Drip tray for workshop hoist - VAS 6208-
• Hose clamp pliers - VAS 6340-

»Carry out the following work sequence«

Removing

• Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50; Body - front; Assembly overview - noise insulation
• Remove charge air pipe »hot« side ⇒ 2.3 Fitting charge air system hose connections.
• Remove charge air pipe »cold« side ⇒ 2.3.2 Removing and installing charge air pipe »hot« side.
• Removing cowling with radiator fan - V7- ⇒ 3.2 Assembly overview - with radiator fan - V7-.

• Remove the generator ⇒ Electrical system; Rep. gr. 27.
• Guide alternator with extreme caution past radiator to prevent damaging it.

• Unscrew coolant return line bolts -arrows-.

• Pull connector -5- off throttle valve module - J338-.

• Remove throttle valve module - J338-.

• Separate connector of Hall sender - G40- -1-.
• Disconnect connector of knock sensor - G61- -2-.

• Loosen Hall sender - G40- bracket -arrow-.
• Drain coolant ⇒ 19 – Cooling.

• Remove coolant hose -arrow-.

• Remove coolant hoses -B, C and D-.

• Loosen securing bolts -3- of 4/2-way valve -2- using T-bar and socket, 10 mm - 3185- and unscrew with Allen key, long reach 5 mm - T10058-.
• Turn thermostat -2- with O-ring -1- 90° anticlockwise and remove from union.

Installing

• Moisten new O-ring -1- with coolant.

• Thread hose -A- behind oil filter module.

The next 2 steps require sparing use of force. Make sure that no damage occurs.

• Thread 4/2-way valve in past ancillary bracket in direction of oil filter module.

• Insert connection -2- of 4/2-way valve with O-ring -1- into cylinder block with slight rotary motions.

Remaining installation is carried out in the reverse order. When installing, note the following:

• Tighten securing bolts -3- using T-bar and socket, 10 mm - 3185-. Specified torque: 15 Nm

Specified torque for throttle valve module - J338- ⇒ 7.2 Removing and installing air filter housing.

• Add coolant ⇒ 1.3.1 Draining.
• Install throttle valve module - J338- ⇒ 7.2 Removing and installing air filter housing.
• Install alternator ⇒ Starter, current supply, CCS; Rep. gr. 27; Removing and installing alternator.
• Installing charge air pipe ⇒ 2 Charge air system.
• Install poly V-belt ⇒ 13 – Crankshaft group.