TDI Coolant Flange replacement

[marvins_dad]

DZLBUG wrote this up for me...

It's pretty easy:

- pop off the air intake hose to get more room
- possibly remove the airbox for more room/sight (note: remove the whole airbox, if you open the top half and expose the air filter you have to replace it because it wont seal right again)
- clamp the hoses to minimize coolant loss, you'll still lose a bunch from the head
- slide the hose clamps back
- remove coolant hoses (pull hard, may have to pry/poke around inbetween the hose and flange with small flat screwdriver to break it loose)
- disconnect coolant temp sender connector
- remove two bolts holding flange in place, 10mm I think.

Tools to make the job easier:
- Cable operated hose clamp pliers (a must for any TDI owner/mechanic)
- Line clamps (order 2) to clamp off hoses...also very useful for fuel filter changes.

Make sure you have a new o-ring seal for the flange. You should also have a new o-ring for the coolant temp sender, and since you're in there...replace the sender for the new style.

So - I did it and took photos.

Looks like it has been leaking for awhile. Take your time and do it when you're able. No big deal...just keep the coolant topped off.

[marvins_dad]

I can confirm that it is a 10mm for both bolts.
Also - I did pick up two "Hose Pinching Pliers" from Pep Boys - $5 each, to help out with the job.

I clamped off the two smaller hoses with the Hose Pinching Pliers and used a Quick Grip clamp to close up the largest hose.

[marvins_dad]

I didn't have the cool remote clamp do-hicky...but it would have been nice!

Since I don't have an airbox - I was able to use pliers to get to both the forward clamp and the one at the bottom. The one on the back was hard to get to.
I removed the electrical or whatever loom in front of the flange so I had clear access.
Then had to use a vice grip needle nose and screwdriver to rotate the back clamp so I could reach it with pliers.

When I pulled the bottom hose off, it dumped quite a bit of coolant. All that was in the block. I took pics of the coolant bottle before and after to show about how much coolant had to be replaced.

[marvins_dad]

Next - removing the Sensor...use a straight screwdriver to do the job.

[marvins_dad]

Much cleaning necessary to make sure that the block is clear of the crusted coolant before replacing...

After cleaned, I replaced with the new sensor (it comes with the seal - apparently all VW's except the Toureg use this same sensor).

[marvins_dad]

Reverse the steps - put back in the sensor clip, then all three hoses and the two bolts back to the engine block.

Of course replace the braided cable back in their clips.

[marvins_dad]

Here is the amount of coolant I had to replace...

[marvins_dad]

After this I ran the engine to check for leaks and changes in the coolant reservoir.

Then a quick run to the car wash to clean the engine to get rid of the coolant and clean the block with degreaser and the high pressure hose to make it "show worthy" again...or at least clean it up so you can tell if you have any more leaks in the future.

[marvins_dad]

Any questions or comments - post them on the following thread...

http://newbeetle.org/forums/showthre...962#post518962