Thermostat replacement

**pg20** · 25-10-2009,06:19 PM

How difficult is it to replace a thermostat on a 96 1.9 TDI? My car is refusing to heat up and I suspect it may be the thermostat (had the same issue on my last A4 but I let a garage sort it). I've had a look under the bonnet this afternoon and think I've located the thermostat but not sure. So if anybody can tell me how difficult it is to replace and confirm the location of the thermostat it would be most appreciated.

**crashcarter** · 25-10-2009,06:28 PM

its underneath the engine on the left hand side (passenger side) just 2 bolts theres a little bracket in the way just whip that of as well it will make it easier watch you dont get a mouthfull of antifreeze.

**pg20** · 26-10-2009,09:47 PM

Many thanks for that. What about draining the coolant and then refilling, is it straightforward?

**crashcarter** · 26-10-2009,09:59 PM

yes most of the coolant will run out. refilling is straightforward just dont try to top it up to fast. when you say your car is not heating up do you mean at the tempature gauge or the heater??

**pg20** · 26-10-2009,10:15 PM

It's the temp gauge that isn't going up to 90 degrees. Had the same issue on my 1.8 avant and after a lot of faffing around it turned out to be the thermostat. If this doesn't work will try the temp sensor.

**Pete@ECSTuning** · 27-10-2009,07:27 PM

Here is a full cooling system instruction link:
http://www.pvv.org/~shane/stasj/pics...components.pdf

**Polis** · 27-10-2009,09:43 PM

i'm new here, so sorry if i'm asking an old question, but does anyone know how to change the thermostat in an 1.6 audi b5 engine? maybe there's a DI but i couldn't find one. please help

**pg20** · 31-10-2009,06:34 PM

Just spent the last 3 hours doing the thermostat. TBH it was slow due to my skills rather than a particularly complex task. Also, after fitting the new thermo I started to refill with coolant and the thing started to leak so had to take it all off again... turned out the new o ring didn't seal properly so had to end up using the old one. Thankfully it looked in good condition and it isn't leaking now. I've ran it up to temp and it sat just below 90° but I need to give it a road test to make sure it's ok. Only thing I didn't replace was the tray that sits under the engine, just ran out of light so will have to replace it tomorrow. BTW costs: Thermo kit £9.37 and coolant £15 for 5ltre concentrate = £24.37. Was quoted anything from £50 - £100 by three local garages.