When to replace the Thermostat on your VW POLO
Recommended replacement interval for the part category Engine thermostat : 50000 km
Important!
This replacement procedure can be used for:
VW Polo Classic (6V2) 68 1.9 SDI, VW Polo Classic (6V2) 110 1.9 TDI, VW Polo Classic (6V2) 57 1.7 SDI, VW Polo Classic (6V2) 90 1.8, VW Polo Classic (6V2) 90 1.9 TDI, VW Polo Classic (6V2) 100 1.6, VW Polo Classic (6V2) 64 1.9 SDI, VW Polo Classic (6V2) 75 1.6 View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

Tools
Replacement: engine thermostat – VW POLO CLASSIC (6KV2). Tools you might need:
Torque wrench
Drive socket # 7
Drive socket # 10
Drive socket # 13
Ratchet wrench
Fluid container
Funnel
Fender cover
Replacement: engine thermostat – VW POLO CLASSIC (6KV2). Tip from AUTODOC:
  • Check the condition of the coolant every time you replace the thermostat. Change the coolant if necessary.
  • Please note: all work on the car – VW POLO CLASSIC (6KV2) – should be done with the engine switched off.
Carry out replacement in the following order:
  1. Step 1
    Open the hood.
    Step 2
    Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
    Step 3
    How to change Thermostat on VW Polo Classic 6kv 1995 - free PDF and video manuals
    Unscrew the coolant reservoir cap.
  2. Step 4
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    Prepare a container for fluids.
  3. Step 5
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    Loosen the coolant hose clamp. Use a drive socket #7. Use a ratchet wrench.
  4. Step 6
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    Detach the coolant hose.
  5. Step 7
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    Drain the coolant from the engine.
    Replacement: engine thermostat – VW POLO CLASSIC (6KV2). Tip:
    Caution! The coolant can be very hot.Wear gloves to prevent contact with hot liquid.All work should be done with the engine stopped.Wait until the coolant has completely flowed out of the drain hole.
  6. Step 8
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    Unscrew the thermostat housing fasteners. Use a drive socket #13. Use a ratchet wrench.
  7. Step 9
    How hard is it to do yourself: Thermostat replacement on VW Polo Classic 6kv 1.6 2001 - download illustrated guide
    Remove the thermostat housing.
    AUTODOC recommends:
    Replacement: engine thermostat – VW POLO CLASSIC (6KV2). Do not use excessive force when removing the part as this may damage it.
  8. Step 10
    Need to know how to renew Thermostat on VW POLO 2002? This free workshop manual will help you to do it yourself
    Remove the thermostat.
    AUTODOC recommends:
    Replacement: engine thermostat – VW POLO CLASSIC (6KV2). Do not use excessive force when removing the part as this may damage it.Caution! Coolant may leak out of the coolant lines and thermostat housing.
  9. Step 11
    Changing of Thermostat on VW Polo Classic 6kv 2003 won't be an issue if you follow this illustrated step-by-step guide
    Install a new thermostat.
    Replacement: engine thermostat – VW POLO CLASSIC (6KV2). Tip:
    When installing, do not use excessive force to avoid damage to the part.
  10. Step 12
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    Install the thermostat housing.
  11. Step 13
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    Tighten the thermostat housing fasteners. Use a drive socket #10. Use a torque wrench. Tighten it to 13 nm torque.
  12. Step 14
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    Attach the coolant hose.
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DIY VW Polo Classic (6V2) Thermostat replacement - online guide
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