Removing and installing front coolant pipe, Polo: VW 1.6 TDI (CAYA, CAYB, CAYC)

🧭 Before you start

Fits: VW Polo 6R (2009–2014)

• Opens: coolant
• Renewed: gaskets

Don't miss

• Disregard (item 4).
• Disregard (items 2, 3, 4)
• Renew gaskets, seals and O-rings.Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic Parts Catalogue (ETKA).

🔧 Engine codes this applies to

📋 Procedure

1. Drain coolant (see the separate procedure).
2. Remove air filter housing (see the separate procedure).
3. Remove oil filter bracket with engine oil cooler
4. Country-specific version for cold countries: Disconnect electrical connector (2).
5. Remove crankcase breather hose (1), press release buttons for this.

6. Pull off vacuum hose (arrow).
7. Unscrew bolt (3), swing air pipe with inlet connection to rear and pull off from turbocharger. [Note: Disregard (item 4).]
8. Unclip wiring harness from retainer (arrow).
9. Free wiring harnesses (arrows) and electrical connector (1) at bracket.
10. Remove air intake hose. To do this, loosen hose clips (1, 2).
11. Remove bolts (arrows).
12. Free electrical wiring and hoses on left air pipe using removal lever80 - 200.
13. Loosen hose clip (1) and remove left air pipe.
14. Disconnect coolant hoses and free them, loosening hose clips (1) to do so. [Note: Disregard (items 2, 3, 4)]
15. Remove electrical connector (2) for Hall sender G40 from retainer and separate.
16. Remove bracket from front coolant pipe.
17. Remove coolant hoses, loosening hose clips (1) and (3) to do so.
18. Undo bolts (arrows) and pull front coolant pipe off cylinder block towards the left. [Note: Renew gaskets, seals and O-rings. Secure all hose connections with the correct type of hose clips (same as original equipment) Electronic Parts Catalogue.]
19. Clean or smoothen sealing surface for O-ring.
20. Moisten O-ring with coolant and slide onto front coolant pipe.
21. Push front coolant pipe into cylinder block.
22. Installing intake hoses with screw-type clips (see the separate procedure).
23. Install charge air pipe (see the separate procedure).
24. Install air pipe with inlet connection.
25. Install oil filter bracket with engine oil cooler (see the separate procedure).
26. Install air filter housing (see the separate procedure).
27. Replenish coolant (see the separate procedure).

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