96 Golf, reconnecting water hoses

Do you mean O-ring as in a ring of rubber? Or do you mean a piece of metal of large size?

If you are talking metal here, I think it is common to use worm-type radiator clamps rather than original clamps.

NOT being a smart ass at all, but I had much easier time replacing those rubber water manifolds after pulling off the front end. I was replacing the fan (couldn't wiggle it out the easy way). Also did the fan belt (yes, there is) and anything else that was a wear item that looked like a pain to get at. Oil change is remarkably easier with the oil filter RIGHT THERE :) Not that it's a major pain anyway...

On balance the cooling system on these A3's is a bad design IMNSHO. Looks like something given to a bunch of fresh-out engineers with too little supervision. Between all the problems they had with fans, goofy "hose" designs, having to burp the system and refill after every heat cycle a couple times, the odd oil cooler that leaks... It's just goofed.

That said, even with all the problems it does work. Just a pain to fix when needed.

Mark '95 Jetta GLS

How hard was it to remove the front end? Is it just a matter of removing a number of bolts and screws? I can't see how there would be much more to it.

In this thread, what is a front end on a car, and what is an O-ring?

It was a pain to do by myself, mostly because it's bulky. Lots of screws and wiring to disconnect, remove, etc. If you have a helper around, might be easier?

You'll also probably wind up breaking the grill mounting tabs, unless it's different on the '96s. I noticed they did change the grill at some point after '95 to a "one piece" grill instead of the two piece one on my '95. Anyway, a large blob of RTV on the busted tabs has held them in place better than the spacers on the shuttle :)

Another, less involved idea would to be to use one of those hose tools. Kinda look like a metal finger. Here's one. Available at AutoZone or someplace similar.

Just be careful not to mess stuff up with the pointy end. It does help seat or unseat stubborn hoses.

Mark '95 Jetta GLS

It wasn't that hard. I had to replace the radiator fans on a 94 Jetta.

I have a picture of where the bolts are but it is pain in the neck.

If you do it, have a helper as the whole front end comes off in the one piece.

I mentioned two hoses with emphasis on the lower one. The upper one was rubber going over hard plastic and I did use a worm hose clamp instead of the original spring type to replace it. The problem is the lower one which is a hard plastic angle over a hard plastic nozzle with a rubber O ring making the seal. Once the plastic angle (which is connected to a rubber hose further back) is pushed over the narrower diameter plastic nozzle that has a groove to capture the O ring, then the clip that I mentioned must be placed in line with two slots in the angle and pushed down. There is simply no room or access to position the clip at exactly the right position and angle and then apply force toward the center of the hose to seat it. It's pretty clear that this plastic-plastic design is because a rubber hose, probably even a molded one, could not tolerate such a sharp angle.

Ray