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Volkswagen EuroVan: 1992-2003 (T4) stuck thermostat / how to remove it?


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Last Post: Feb 11, 2013 11:32 PM Last Post By: Kauboi
turbo+

Posts: 4
Registered: 05/05/12
stuck thermostat / how to remove it?
Posted: Feb 11, 2013 2:16 PM
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I got a 2003 Eurovan with 154k miles on it. Even in sunny San Diego it takes quite a while to get the engine to operating temp - 190F and on long downhill parts of the road, the temp gauge goes down. All a sign of a stuck thermostat???
How do i get the thermostat out - there is just no space to get my tools in. I know the location, but i can't get there to remove all three bolts. Do i have to remove the whole thermostat housing that is attached to the engine block and disconnect all the hoses - i would love to avoid that if there is some kind of trick? ;-)
any causion i have to use unbolting the thermostat housing? i got the two long bolts out that attache the housing, but the housing didn't move (i didn't force it)
thanks in advance for any tips!!
FKH161

Posts: 7,661
Registered: 12/29/05
Re: stuck thermostat / how to remove it?
Posted: Feb 11, 2013 3:24 PM   in response to: turbo+ in response to: turbo+
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The housing is held on by three 5mm bolts... the 2 long ones that you removed, as well as one short one towards the rear of the vehicle.

It's a good idea to replace the whole assembly as well as the pipe that attaches to the housing and runs across the front side of the engine to the water pump.
Kauboi

Posts: 6
Registered: 02/11/13
Re: stuck thermostat / how to remove it?
Posted: Feb 11, 2013 11:32 PM   in response to: turbo+ in response to: turbo+
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I replaced mine from underneath, On ramps, with the belly pan removed.It wasnt too terrible after all, with the rear housing bolt being removed by ''feel". One essential tool is proper hose clamp pliers. Mine are the locking/cable type, and I wouldn't do the job without them. Also, the allen wrenches/sockets that have a "ball" shaped end are a big help.My original thermostat was missing part of its rubber seal, and would take forever to warm, like yours.

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