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Non VW Group Diesels This section is for discusion of Non VWGroup Diesels.

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Old February 27th, 2012, 09:40   #1
josh8loop
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Default 2005 E320 CDI 92 Deg C Thermostat....

Fellas,

Noticed my new to me 2005 E320 CDI engine temp is running lower than it should. It's indicating 60C in colder climates, and only got to around 80C in Florida here. I verified temps with a digital thermometer in the tank. I need to find the highest temp OEM style T-stat I can find for it. Looks like the originals may have been rated for 87C(depending on regions emissions requirements), but were possibly respecified to 90 or 92C. Pelican parts has the Wahler brand 92C T-stat for it, and so does KO performance:

http://www.koperformance.com/catalog...hermostat.html

Looks like KO performance with the free shipping is a better deal. Anyone have an other vendors at reasonable prices?
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old February 28th, 2012, 07:46   #2
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I ordered from KO performance. They had the 92 Deg C Wahler unit with the coolant temp sensor included with the housing. Some of the manufacturers are sneaky and don't include a new temp sensor-Beware. Really the $57.00 for the thermostat, housing and a temp sensor isn't too bad if you think about it. The ALH temp sensor is $15, housing is $7, and the thermostat can be from $7-$35. Add is all up, and the $57 seems really reasonable. I plan on disecting the old T-stat assembly to see if there would be a way to retrofit a 205 Deg F T-stat in there like I have done on my ALH.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old February 28th, 2012, 08:52   #3
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Just found a diagram of the coolant loop for the 05 and 06 E320 CDI:

http://www.benzworld.org/forums/w211...eks-cdi-6.html


Post number 51 If anyone is interested
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!

Last edited by josh8loop; February 28th, 2012 at 08:57.
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Old February 28th, 2012, 11:01   #4
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Rock Auto has it for $44.79

It's a Gates part: http://www.rockauto.com/catalog/moreinfo.php?pk=1860442
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Old February 28th, 2012, 12:53   #5
josh8loop
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That's rated for 92 Deg C? Also looks like black plastic instead of the aluminum the original is.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old March 5th, 2012, 17:27   #6
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I found the quality of the wahler 92 C unit to be on par with what I expected from a quality german manufacturer. Just did my Thermostat last friday evening which took about 45 minutes. Used a vacuum device to remove all the coolant from the reservoir, and then went to town on the thermostat. I didn't remove the oil filter cap like most others do, and didn't have too much trouble getting the old T-stat out and the new one in. I didn't end up loosing a drop of coolant BTW. There are 4 fasteners that secure the T-stat. 3 in the T-stat framework that secures it to the head, and one that goes in through the bracket at the front of the engine directly into the T-stat housing. I was struggling to reach 80C, and now run 92C easily. I believe I picked up a mpg or two from the change FWIW.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old March 10th, 2012, 06:35   #7
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Added my(wifes actually) 2005 E320 CDI to Fuelly so I can track MPG's etc. I like it because not only does it track mileage, but you can add repair notes to it so you have a record of what was done on the car. I recently fixed an oil leak on the pasengers side top of the motor that seemed to be coming from the oil fill cap area, and cleaned the EGR valve, and the MAF sensor. Hopefully I will see some MPG gains from it all. Next on the list is fuel filter, and air filter along with a diff fluid flush....
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old March 10th, 2012, 22:36   #8
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I made preps for the Tstat while at work today. I could have done it but I forgot to pick up a female torx set. I have lots of photos of the topside of the engine and I will post the Tstat photos tomorrow or the next day. Gonna do the change out while at work Sunday evening.
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Old March 11th, 2012, 05:15   #9
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Cool, glad to hear you are getting things in line for the swap. Looking forward to some photos of the process. I believe I will be making a quick YouTube video soon of the replacement of a couple seals that are under the air/oil separator. Mine was seeping oil and causing the start of a big mess. Doesn't seen to be much in the way of DIY type videos for these vehicles, so it's wide open for us to contribute.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old March 11th, 2012, 13:12   #10
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Could you post your link to the 50x4mm o-ring that you found. I couldn't find it from the benzworld post.
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Old March 11th, 2012, 17:22   #11
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No problem-sounds like you have a bit of a leak there too I got it from AutoHausAZ and it's a thermostat O ring/seal from a 2002 VW Jetta TDI part number 059121119. Here's the link:

http://www.autohausaz.com


Also available from NAPA autoparts too. I have made a video that will hopefully be live some time tonight on the repair.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old March 11th, 2012, 18:34   #12
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Here's the video:

http://www.youtube.com/watch?v=8VEfE...1&feature=plcp


..
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old March 18th, 2012, 19:28   #13
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Thermostat change video:

http://www.youtube.com/watch?v=jiV9u...1&feature=plcp
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old March 19th, 2012, 13:14   #14
Derrel H Green
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Quote:
Originally Posted by josh8loop View Post


Excellent video. Thank you.

Now I've got another small project to perform.
Did not realise that mine was leaking slightly until I viewed your presentation.

Also, how did you get your entire engine to shine as it does?
The engine compartment looks like it is brand new!

When you do your rear end gear oil change, see if the ratio is stamped
on the
carrier as it used to be on the older models. Should be something like 2.65.

Thanks again.



Derrel
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Old March 20th, 2012, 00:59   #15
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Thermostat changed on mine. Engine heats up properly and fuel economy may have improved. Did not remove oil filter and didn't drop any fasteners in the engine.

My next fill up will be with 49+ cetane D2 from an independent refiner/supplier (MFA oil) in MO. Lets see if the low rpm lugging improves with better fuel.
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