New MK2 GTI Project - help with leaking thermostat housing needed

[Oilburner]

Hey All

Been lurking around the MK5 section as i have a GTTDI as my daily wheels...

But Yesterday, i took delivery of my new 8v project... and very nice it is too!! the plan is to turn it in to a track weapon but keep road legal for the B road blasts etc... Cant wait to get cracking...

However, first i need to sort the leaking thermostat housing. Having removed the cover and removed the thermostat and seal, it all looks ok. I buy a new thermostat complete with new seals, and the new one comes with 3 rubber seals and one cork type gasket. One of the new seals is identical to the old one and fits perfect, the other 2 rubber seals are slightly smaller and the cork gasket is no where near the correct size or shape to fit. So i put it all back together with the new seal - and still its pissing water..

Have i got all this the right way round? - Thermostat in first, then the round rubber seal, then the cover..? what am i missing?

Any help would be most appreciated

Cheers

Rich

[earlymk2]

I changed my thermostat on my mk1 caddy yesterday. I know is not a golf but i believe that they all run the same pump/housing. Anyway the seal that i got with the stat, was one that went around the out side of the stat, like a tire on a wheel. The one i put on my Golf 2 months ago was the same as you have described. I fitted the same as you have done with no probs from what i can remember. Is the plastic housing got a crack in it by and chance? Sorry i cant be any more use. Hope this helps

[Dolly]

could be a dodgy stat housing, the plastic bit it sits in, these are only a few quid and id of probably changed that when doing the stat. if it still leaks after a new stat hosing and seal then id be inspecting the water pump for any cracks/damage ect.

[Oilburner]

Cheers...

Im sure i have it right with the seal. There are no cracks or any damage at all to the cover, it seems to be coming from around the rear bolt. Since posting i almost got the leak to stop by undoing and then putting back on and tightening up each bolt a turn at a time incase it was not sitting level, all fine untill i snapped the bolt...

luckily the rest of the bolt came back out easily, so once i have some replacements i can try again.  

[rubjonny]

maybe the flange itself, they're only plastic and warp with age, a new one wont be that expensive.  The stat will only go in 1 way, and it goes in 1st, then the seal, then the flange

[Oilburner]

cheers rubjonny!!

To make matters worse, i have now managed to lose the one good bolt to compare to any replacement, leaving me with the stub of the broken one. Any idea what size they are? The head is 10mm, but what about the thread?

Cheers Ladies & Gents

Rich

[rubjonny]

ask and ye shall recieve:
N   010 222 8 - M6x22

You need washers for them too, vag part number is N   012 226 5

[Oilburner]

Brilliant, thanks for the info. nipped in to the local dealer armed with part number and 3 replacements will be here midweek. Added bonus the guy managed to order up a replacement cover 

Hopefully will get it sorted

Thanks again for all the help

[Oilburner]

Leak is fixed! new bolts and plastic cover have sorted it right out! Thanks for the help...

Only problem is, went to close the bonnet and the damn catch wont engage and lock the bonnet down... aaaaaahhhhhhhhhhhhhhgggggggggg

Im hopefull that its easily accessable from behind the grill and will be an easy fix 

[Mr Blue]

Just make sure you dont drive with the bonnet like that. Being serious!

push the bonnet release handle back down if its stuck up and then try closing it. quite common.