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Old March 22nd, 2012, 10:53   #3
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Join Date: Aug 2004
Location: Northern Minnesota-55744
Fuel Economy: 52+ average lifetime '01

Originally Posted by jcrews View Post
It's very easy. Get a new thermostat with o-ring, preferably genuine/OEM.

Place a catch pan under the radiator and open the drain by twisting it and pulling it out until it stops. Open the overflow reservoir cap to speed up draining. Close the radiator drain once the water stops draining Use spring clamp release pliers to release a hose from the oil-water heat exchanger below the oil filter housing. Replace the hose once the water stops draining.

You can skip the above if you put a large catch pan under the engine and allow the water to spill out of the thermostat housing, but it will make a big mess.

Just below the injection pump, remove the plastic water nipple from the water pump housing on the engine block using a 10 mm 1/4" drive socket and long (6 inch) extension. Carefully try to release the nipple from the thermostat by twisting it.

Clean the sealing surface on the engine with a rag.

Install the new thermostat and seal in the nipple. There are two tabs that hold the thermostat in place. If those are broken, remove any loose pieces and use a loop of string or wire to hold the thermostat in from the open end. The string or wire will be removed once the nipple is secured in place with the screws. Do not overtighten the screws.
Yep, follow the above steps, it doesn't get much easier.
Oh, one thing. I recommend an OEM stat. I've tried a few others and so far haven't been happy with any except 1 out of 2 Wahler (which isn't good average). The OEM ones are about the only ones that work with the clips/tabs in the coolant flange. They aren't neccessary, but do make it a bit easier.

2001 Jetta TDI GLS Silver-current driver (salvage)permanently vented-Panzer Plate-Sprint 520s-ScanGauge-CheckTemp III-ZeroStart heater-CAT 2 filter
2003 Jetta GLS Black w/leather (New Project Car) fixer-upper w/broken TB
2004 Cadillac SLS (wife's)
1999 GMC Suburban (It's MN-you need one)
197? Shibura 2cyl diesel 4WD tractor-loader/brushhog (very handy unit)
196? International TD340 Dozer-w/Drott 4-in-1 bucket/back ripper attachment
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