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Last Post:
Jan 22, 2009 7:15 AM
Last Post By: MartinS
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Posts:
9
Registered:
07/18/07
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replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 19, 2007 6:59 PM
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will the cd help an average joe replace the water pump, hoses, and thermostat and its housing? will i need to remove numerous parts? i can see the collant coming from underneath the thermostat housing, and it seems like it may take a lot of removing parts to get to it. any help will be of great use. i have considered selling this car, but if i receive some advice, i might purchase the cd and try my hand at fixing my passat instead of allowing a mechanic's view and quote of $1500 to force me to sell it.
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Posts:
6,346
Registered:
12/29/05
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 19, 2007 9:26 PM
in response to: samartq45
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The cd's are great... but don't expect step-by-step instructions
on everything.
Attached is the first 1/3 page that is listed in the cd as:
Coolant thermostat housing, disassembling and assembling
....basically just an exploded view.
When clicking on "Connecting the coolant hoses to thermostat
housing => Page 19.5"... you get an exploded view of the
surrounding coolant hoses & how/where they attach.
As with any repair, it comes down to common sense. Remove
what you must to get at what you want to remove. 
Buy the cd, it will help more than not having any info and
you can always sell it with the car. |
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Posts:
9
Registered:
07/18/07
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 20, 2007 6:30 PM
in response to: FKH161
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thanks for your very quick response and information
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Posts:
6,346
Registered:
12/29/05
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 20, 2007 7:22 PM
in response to: samartq45
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Remove the ignition coil pack (4 5mm allan bolts) for more
room/access.
You can leave the ignition wires attached, disconnect the
harness plug on the top and then you can place the coil pack
on top of the engine out of the way.
The thermostat housing attaches to a plastic pipe that runs
along the front of the engine and sits in a hole behind
the water pump.
This pipe likes to break or can cause problems down the road, so
I would recommend changing it as well while you are in there.
I believe that you can buy a metal version of that pipe (non
VW)... which would be a better choice!
The electric coolant after-run pump is probably old & leaking
as well.
At 10yrs old, you'll find lots wrong with the car/engine... which
by now is to be expected and normal.
Once sourted out though, it'll be good to go for another 10 yrs! |
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Posts:
189
Registered:
12/11/04
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 20, 2007 9:13 PM
in response to: samartq45
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Fairly easy job 1 - 1.5 hours. Buy new housing, and replace thermostat while you in there. Most of the time it's the housing warping out of shape and the "O" ring for the block to housing seal leaking. Replace all "O" rings on the three sensors and be careful not to damage any of the hoses (new ones are expensive). Housing is fairly cheap as I remember.
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Posts:
189
Registered:
12/11/04
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 20, 2007 9:27 PM
in response to: samartq45
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Replacing the water pump is another story. The engine must be taken loose from the three mounts and lifted so the pump will clear the frame rail. You need and engine support and a few special tools for that. That is probably an expensive job compared to the thermostat housing. I would replace the thermostat housing first and then see if it still leaks. The thermostat leak can run across the supply pipe and make it look like a water pump leak.
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Posts:
9
Registered:
07/18/07
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 22, 2007 2:58 PM
in response to: Honest Lou
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hello, i was at the point of selling this passat, but do to the replies, i'm thinking about trying to fix it. 57,000 miles is the reading, for my mom rarely drove it. i saw the coolant leaking from underneath the housing, so is it more-than-likely that the water-pump doesn't need replacing? i was quoted $1500 to fixed the leak ( 11 hoses, water-pump, and thermostat and housing )? original problem was white smoke coming through the vents and coolant leaking from the area of teh thermostat housing. i've spent nearly $4000 on this car over the past 4 years, and just had a new air-conditioner installed. i was offered $900 from mechanic, and was about to except it. i'm an average joe, and though i have dabbled with engines, this car is a enigma.
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Posts:
9
Registered:
07/18/07
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 22, 2007 3:03 PM
in response to: FKH161
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hello, i was told 11 hoses, water-pump, and thrmostat housing needed to be replaced. if i was to try and fix it myself, what would be the cost to replace all items mentioned and other parts that should be replaced?
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Posts:
189
Registered:
12/11/04
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 22, 2007 7:41 PM
in response to: samartq45
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Some of the hoses are expensive, one around $100, I would only replace them if they need replacing. Water pump and "O" ring $45 (new not reman). Tool to get water pump off, $20. Thermostat housing $20, new thermostat, $10, I am guessing at this one I don't remember. Hose clamp pliers set to get clamps loose, $20 (these are really handy for those self tightening clamps). Engine support for water pump removal, $100 or so (can be used over on the next job). My estimate on time, 4 hours or so for all the work, more the first time you do it. Much less than $1500.
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Posts:
1,409
Registered:
12/09/03
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jul 24, 2007 11:41 AM
in response to: Honest Lou
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I usually don't post against what a garage says, but sounds like overkill. Only replace the bad hoses(if any) and the entire tstat and housing. That whole housing and tstat should be under 100 for all the parts if you get aftermarket. Waterpump is a little tougher, so only do it if leaking. I do the housing in one piece, 3 5mm allens hold it, one is down in and hard to see. If you have the parts first, you'll have an idea where to find it. I don't unhook anything else(done enough) but the cable operated hose clamp tool will be a great investment over the plier type. Just be carefull pulling it off the pipe to the w.p., and replace that and the sensor o-rings as well.
The thing that does concern me is the smoke/steam from the vents. It would have to be a healthy leak to make enough for the blower to suck in unless you have a heater core issue.
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Posts:
1,739
Registered:
10/31/03
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Dec 12, 2008 11:01 AM
in response to: samartq45
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Can someone post a link for the replacement metal pipe that was recommended earlier in this thread?
I need to do this job on my '95 Passat GLX, manual trans. I think all my coolant hoses have been recently replaced, but it's ******* coolant from the back side, or possibly at the O-ring of the thermostat housing. For now it is only doing it when the engine is warm, but a repair is definitey now on my short list. I've already ordered a new thermostat housing, with O-rings and a new thermostat.
I'm also considering replacing the coilpack, but at $250 new am researching a good used one. Mine is likely original, has some good sized cracks in the plastic, and occasionally will misfire when wet.
Thanks,
Stan
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Posts:
6,346
Registered:
12/29/05
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Dec 12, 2008 10:56 PM
in response to: wohlfarth
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Posts:
1,739
Registered:
10/31/03
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Dec 16, 2008 10:47 AM
in response to: FKH161
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Thanks for the links Tom.
The problem has spread into a starter bushing issue. I haven't even touched the thermo housing yet.
I'm going to look at another wagon this weekend; '96 GLX, red w/black leather.
The '95 is stuck on ramps and I'm forced to drive something a little more 'vintage' for now.
-Stan
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Posts:
11
Registered:
12/28/05
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Dec 16, 2008 3:22 PM
in response to: wohlfarth
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Stan,
I have heard of people doing an MSD ignition conversion, and part of the process is moving the ignition module off of the engine to a bracket that mounts where the coilpack was. With as much problems as these coilpacks tend to be (and as expensive as they are), it might be a worthy upgrade. I just replaced my coilpack a year or so ago, but if mine takes a dump again, I think that is the route I will likely go.
Also, those metal pipes are nice, I no longer use the plastic ones at all when they come in to the shop. We use the gruven parts version, A+ Quality and fit.
Bummer about the starter bushing, my starter has been giving me fits for a while now, I just cant justify the money until it dies entirely though. In the mean time I suppose I will just continue to park on hills! =)
Good luck on the 96, you dont see a lot of red B4s around here, and the step up to OBD2 would be nice as well!
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Posts:
1,739
Registered:
10/31/03
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Dec 16, 2008 5:15 PM
in response to: IDriveBug
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I picked up a 12mm tap to pull the starter bushing out tonight. Hopefully I can get the old starter (or new starter) back in and working tonight.
Snow is expected after midnight and I really don't want to drive my old bus again tomorrow if they salt the roads.
I've got the gruven metal crack pipe link bookmarked.
http://gruvenparts.com/website/cart/cart.php?target=product&product_id=255
And like the version with the chrome drain valve.
Thanks for the tip on the MSD ignition conversion. My coil pack hasn't failed, yet, but it does miss sometimes when the weather is wet. I sealed up the cracked/broken plastic casing around the coil heatsink with epoxy, but haven't had a chance to try it out yet due to the starter bushing failure.
My coolant leak is coming from the back side (toward passenger compartment) of the thermostat housing. It only seems to leak after the engine is warmed up. Likely it's the O-ring where the housing mounts to the engine, but I haven't pulled it apart yet to confirm this.
-Stan |
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Posts:
1,739
Registered:
10/31/03
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Dec 17, 2008 11:02 AM
in response to: wohlfarth
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I ended up needing to use a 1/2 inch tap to get most of the starter bushing removed. Still had to dig out the last remnants of it too. Also tried the old starter (rebuilt in '05) but it didn't work with the new bushing. New starter works fine though.
Epoxy repair to coilpack is working well, no misfires and there was plenty of wetness this morning with a couple inches of snow turning to rain.
But the best news of all, no coolant leak! I put two bottles of bars leak in the reservoir, let it idle for 15 minutes or so, then checked for leaks. Sure enough it was leaking, so I revved up the motor a bit to get the coolant/bars leak circulating better. The leak quickly stopped! After that I took the car out for a test drive and haven't seen any coolant leaking since.
My new Nokian GR2 tires are great in the fresh powder too.
The old bus is tucked away safe and dry in the garage. It's nice to have the daily driver back in service just in time for our first real snow of the season.
-Stan
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Posts:
1
Registered:
01/21/09
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jan 21, 2009 5:37 PM
in response to: samartq45
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Posts:
54
Registered:
01/06/04
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Re: replace 1997 passat 4dr vr6 thermostat housing and pump
Posted:
Jan 22, 2009 7:15 AM
in response to: FKH161
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The eBahn desktop DVD is the same as the download - but there are older versions of the DVD available. This is more of an issue for newer vehicles, where the information is still changing a lot. That said, it's possible to get a DVD with older information on it. How can you tell? Well, it doesn't really matter, since the "Check Web For Updates" function will bring you up to date.
Message was edited by: MartinS
Message was edited by: MartinS |
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