Matt Devo

I used the writeup by Mark955 on AW, but thought I'd add some pics for the more visually-oriented =). All pics can be clicked for larger versions.

Thermostat is part # 06B-121-111-G. my original was a -D, and I believe G is being replaced by H (as per my invoice).

the operating area:

<a href="http://www.putfile.com/pic.php?img=6787261" target="_blank"><img src="http://img2.putfile.com/thumb/10/27616204426.jpg" alt="Click to enlarge"></a>


Step 1: Drain coolant (sorry no pics)

Remove bottom belly pan. Remove coolant reservior tank cap. Remove plastic clip holding coolant sensor in place at lower radiator hose/pipe. With bucket/catch pan underneath, remove sensor and let coolant drain.


Step 2: Remove upper radiator hose

remove the small hose connecting the coolant reservior to the upper radiator hose. Then remove the larger hose from the hard pipe running along the intake and from the radiator. You'll need to pop up (but not off) the metal clip holding the hose to the radiator, then firmly pull back:

<a href="http://www.putfile.com/pic.php?img=6787264" target="_blank"><img src="http://img2.putfile.com/thumb/10/27616204457.jpg" alt="Click to enlarge"></a>

hose removed:

<a href="http://www.putfile.com/pic.php?img=6787265"><img src="http://img2.putfile.com/thumb/10/27616204538.jpg" alt="Click to enlarge"></a>


Step 3: Remove intake hose (throttle body-to-intercooler)

remove driver's side headlight (not necessary but makes it a lot easier). Loosen clamp at each end and remove hose.

<a href="http://www.putfile.com/pic.php?img=6787257"><img src="http://img2.putfile.com/thumb/10/27616204311.jpg" alt="Click to enlarge"></a>


Step 4: Remove throttle body

remove electrical connector and 4 hex bolts (5mm):

<a href="http://www.putfile.com/pic.php?img=6787263"><img src="http://img2.putfile.com/thumb/10/27616204437.jpg" alt="Click to enlarge"></a>

removed:

<a href="http://www.putfile.com/pic.php?img=6787262"><img src="http://img2.putfile.com/thumb/10/27616204413.jpg" alt="Click to enlarge"></a>


Step 5: Loosen serpentine belt and slip off of alternator

use a box-end or adjustable wrench on tensioner, pull to the right. Carefully slip belt off alternator (towards front of car). Allow to hang loose below

<a href="http://www.putfile.com/pic.php?img=6787255"><img src="http://img2.putfile.com/thumb/10/27616204357.jpg" alt="Click to enlarge"></a>


Step 6: Remove alternator bolts

remove 4 bolts holding alternator to bracket:

<a href="http://www.putfile.com/pic.php?img=6787254"><img src="http://img2.putfile.com/thumb/10/27616204291.jpg" alt="Click to enlarge"></a>


Step 7: Remove electrical connector and grounding cable from alternator

after removing the 4 bolts, lay the alternator face down on the top of the fan and remove the electrical connector, and the grounding strap. If you haven't disconnected the battery, be sure to cover the grounding strap in tape so it cannot touch other metal surfaces

<a href="http://www.putfile.com/pic.php?img=6787252"><img src="http://img2.putfile.com/thumb/10/27616204166.jpg" alt="Click to enlarge"></a>

alternator removed; grounding strap shown:

<a href="http://www.putfile.com/pic.php?img=6787253"><img src="http://img2.putfile.com/thumb/10/27616204297.jpg" alt="Click to enlarge"></a>


Step 8: Remove vertical support piece from intake manifold to block

remove the two bolts holding the support piece (6mm hex):

<a href="http://www.putfile.com/pic.php?img=6787266"><img src="http://img2.putfile.com/thumb/10/27616204596.jpg" alt="Click to enlarge"></a>


Step 9: Remove bolt from metal hose on t-stat; remove bolt from top of oil cooler

this will allow you to move the hard pipe away from t-stat. On my car, even after removing the bolt I was unable to remove the hard pipe at this time - I had to remove the thermostat from the block, then wiggle it free from the pipe afterwards

bolt holding the hard pipe on the right, two bolts holding the t-stat to the block on the left:

<a href="http://www.putfile.com/pic.php?img=6787258" target="_blank"><img src="http://img2.putfile.com/thumb/10/27616204384.jpg" alt="Click to enlarge"></a>

bolt holding the metal pipe to the top of the oil cooler (as seen from top of intake):

<a href="http://www.putfile.com/pic.php?img=6787260"><img src="http://img2.putfile.com/thumb/10/27616204422.jpg" alt="Click to enlarge"></a>


Step 10: Remove upper and lower hoses fom t-stat. Remove electrical connector on back side

<a href="http://www.putfile.com/pic.php?img=6787259"><img src="http://img2.putfile.com/thumb/10/27616204321.jpg" alt="Click to enlarge"></a>


Step 11: Remove 2 bolts holding t-stat to block, and remove t-stat

(I'm reusing a pic, please don't sue me)

<a href="http://www.putfile.com/pic.php?img=6787258"><img src="http://img2.putfile.com/thumb/10/27616204384.jpg" alt="Click to enlarge"></a>


Step 12: Install new thermostat

install new thermostat, making sure to remove the old O-ring. The new t-stat will include a new one. I wet my finger with coolant and ran it along the O-ring to pre-lube it before installation. Otherwise, install is reverse of removal:

All done - looks just like when we started!

<a href="http://www.putfile.com/pic.php?img=6787261"><img src="http://img2.putfile.com/thumb/10/27616204426.jpg" alt="Click to enlarge"></a>


Disclaimer: this information is for educational purposes only. Poster is not responsible if you somehow manage to blow up your car in the process.

bhvrdr

Did your problems go away Matt?

Eddie Man

time to such a detailed write-up...
Kudos to you for a great job.
Thanks for sharing

Matt Devo

yes sir, thanks for pointing out the problem

forced induxion

perfect...i'm going to use this next weekend.

a4tis™[Bye Turbo]

excellent write-up, i'm def saving this one

bhvrdr

Awesome. Good to hear bud.