Thermostat swap procedures?
 

've been chasing a temperature gauge issue for the past couple of weeks and determined that the thermostat on my 09' TT needs to be replaced. Does anyone have a link to a online tutorial?

-B

No but
 

some folks have had issues with non-OEM thermostats on the Mk 1 making the car run hotter than normal. It appeared that even if the aftermarket thermostat was made by the same Audi supplier, Wahler, the Audi OEM operated differently. Happened to me so I had to replace the thermostat twice so I'd go with an OEM just to be safe. You are the first person I've seen post a thermostat problem in their Mk 2 on the 3 forums I check regularly.

Thank you for the input! My temp gauge would suddenly drop all the way to the left and stay pegged so I thought it might have been the temp sender. I installed a new temp sender and nothing changed.

What I noticed next is that I could not get a significant amount of heat from the HVAC system till I cranked the temp knob all the way to the right. *BINGO* It's gotta be the thermostat!

-B

I finally found a video on the thermostat housing swap and it looks like a ROYAL pain in the ass!


The guy had experience, had a lift, and it took him 15 minutes to remove. Which means it'll be a 2 hour job for me! LOL!

[smiley=bomb.gif]

-B

Its been a few weeks since I've updated this post but here goes.

The main issue with the car was the secondary temp sensor and a bad thermostat.

Attachment 82066

It took me A LOT longer to do this swap due to inexperience and lack of specialty tools. It took me nearly 8 hours because I had to do it TWICE! :x If I had to do it again all over again it would probably take no more than 2 hours tops.

Here are some suggestions to make your experience much easier.

1) Make sure you have a nail laying around so that you can lock the belt tensioner in place.

Attachment 82067

2) I suggest buying a radiator clamp tool. t'll save you a lot of time and frustration! I bought this one from Sears http://www.sears.com/craftsman-cable...p-00947390000P It's nice because it'll keep the clamp locked open as you position the clamp on the hoses.

3) Also pick up a radiator hose pick tool. It's easier to remove the hoses with this tool versus using a screw driver and brute force. http://www.sears.com/unknown-8-quot-...525209?prdNo=6

3) The MK II's have a secondary temp sensor that can only be replace by pulling the alternator. If you're swapping the thermostat, I would HIGHLY recommend replacing the o-ring for the crossover pipe. I had to do my swap twice because I reused the OEM o-ring and it leaked coolant everywhere! I decided to go with a slightly larger o-ring to eliminate any possibility of leaks.

Attachment 82068

4) When reinstalling the alternator besure to thread the mounting bolts back in and tap them with a hammer to get the bushings to recess. If you try to reinstall the alternator as is you'll never get it back on.

Attachment 82069

5) Get a set of torx bits because nearly all of the little fasteners require them for removal.

Good luck!

-B

Also,... You're gonna need a set of triple square sockets to loosen and remove the 2 coolant lines on the right side of the intake.