thermostat refit issues , advice required

[soin]

yep both bolts i did up as tight as i could , with alternator out the way im getting good leverage too , so woud say both bolts are defo tightened well

[KeithyGTI]

Any update on the out come of this topic. Exact same problem here. Im getting quicker at removing and refitting the thermostat now after 4 goes, I can do it in a hour now but still pissing out when up to temp??? Pulling my hair out now. Everything seems to fit fine. Going out for one last go now else it will be a train ride to work today 

[Nino]

Might sound stupid, I did mine about 2 weeks ago took me ages to get the bottom bolt but i did it, ensure the thero is in SPRING end first and then the O ring, Put the O ring in the housing, it should slip into the ridge left in the housing (will make sence when you look at it, I took my housing off) then if you still having a leaking issue I would personally go to VW and get a main dealer part thats what I did Yes it cost me over £35 when I can buy them for £11 for a cheaper part but like the guy at VW said the cheap ones always break and never outlast the VW part also he told me 3rd party parts are prone for leaks.

[theshrew]

You dont need to remove the alternator to get to the bolts they are a bit of a pain but you can get on them think i used a wobbly end extention ( its been a long time since i did mine )

If your getting leaks things to check / do

Make sure when you take the housing off clean the surfaces on it and the engine and bits of rust etc can cause a leak need to be 100% clean 

Fit a new o ring

Cant remember if it has a gasket but if it does fit a new one

Obv fit the stat the correct way round

If you have done all that and you still have a leak you must have a different issue. If i remember correctly the housing is plastic its possible you have cracked it by over tightening the bolts they dont need to be crazy tight.

If you still having trouble check where the leak is comming from you will probably be able to see water marks if wet or you might see likw a white ish staining that will give you a clue 

[james2]

The O ring sits in the plastic housing. I you have broke it hears a cheap one on ebay.
http://www.ebay.co.uk/itm/VW-GOLF-MK4-TURBO-MK4-GTI-THERMOSTAT-COVER-KIT-C202-/190644528146?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item2c634ca412

[KeithyGTI]

You guys are STARS!!! I took the thermostat off again tonight and re fit it with the O-ring on the housing side of the thermostat instead of behind it (on the spring side). Built it up and Hey Presto, NO LEAKS. :embarassed:

 When I removed the original thermo, I remember the O-ring was defo on the spring side and thats why I rebuilt the new one on the inside but obviously that wasnt the case. Thanks guys.

[tokemk4gti.t]

come to think of it, I had the seal on in the wrong order if you get me, thats why mine leaked.

i did eactly the same and los a full tub of noce new g12 gasket has to go in the right way i found out the hard way :s lol and can def get the bolt without removin the alternator i did mine 10 minutes start to finish (the third time )   haha

[Nino]

Glad you sorted it