1.8 SE (ADR) Thermostat replacement

[brollah]

I've finally given it a go to replace the thermostat on my 96 1.8SE (ADR), But the problem is I can't get the damn thing off. It's sat on the drive as we speak, lol

I've gotten to the thermostat housing, removed one of the 2 bolts holding it in place, but I simply can't get anything on the other bolt. It's just too closely recessed behind the water pump to get literally anything on it.

Is this something anyone has come across? Shouldn't getting to the thermostat be a by-the-side-of-the-road job? Rather than a front end rebuild? lol

Any help at all, even a clue would be appreciated.

Many thanks

[Crasher]

I had this the other day, sounds as though someone has done it before with the pump off and used normal hex head bolts rather than socket (allen) cap bolts for a 5-mm key. I just managed to get the bolts out with a thin wall ¼” drive 10-mm socket but it was close to needing the pump off. When I put it back together, I fitted 5-mm hex cap M6 bolts. If you can’t get at it, you will have to remove the pump.

[brollah]

My dad ended up getting desperate with it, he fitted a stud extractor on and just managed to grab it.

Talk about frustrating for what should be such a simple job.

Ironically, the same day we tried to fit new track rod ends to both sides. The passenger side was so badly damaged we're drilling it out after cutting it off. It's so rusted in it's ridiculous. We've snapped spanners, good ones too! lol

The thermostat was the easy bit..

[paulsa4]

if you put heat on it it wi;; free it off, blow torch wood do

[ceemark]

I'm going to change the thermostat on my Passat, same model as the one in this thread, I have one concern, when replacing the thermostat housing, are there any seals that need changing. Or is it just bolted straight back on, and any idea what the torque settings are?

[Crasher]

You must change the O ring and I strongly suggest you fit a new thermostat cover as they often warp and can be difficult to get to seal when re-used.

[ceemark]

Thanks, luckily the old housing was fine, replaced it and it still fitted, turned into a relatively easy job, just a bit fiddly, especially with the bloody brace in the way, and trying to get an allen key in, to remove it is a pig. But it's done now, and feels like a new car.