Volkswagen Golf/Jetta/Cabriole 1990-1999

Thermostat

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REMOVAL & INSTALLATION



4 Cyl. Models


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Fig. Remove the housing bolts



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Fig. Once all bolts have been remove, pull the thermostat housing away from the bottom of the water pump unit



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Fig. Note the position of the thermostat and gasket


NOTE
On some models the thermostat is in the bottom of the water pump housing.

  1. Place a large drain pan under the vehicle to collect the coolant.
  2.  
  3. Remove the radiator cap and drain the cooling system.
  4.  
  5. Loosen one bolt at a time until coolant begins to flow.
  6.  
  7. Remove both bolts and remove the thermostat.
  8.  

To install:

  1. Install the new O-ring.
  2.  
  3. Torque the housing the bolts to 7 ft. lbs. (10 Nm).
  4.  

VR-6


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Fig. Exploded view of a VR6 thermostat housing

On 6 cylinder models, the thermostat is mounted in the housing. The thermostat housing is located on the rear of the cylinder head.

  1. Drain the engine coolant.
  2.  
  3. Remove the mounting bolts from the flange.
  4.  
  5. Remove the flange and the thermostat.
  6.  

To install:

  1. Install the new thermostat and O-ring.
  2.  
  3. Install the thermostat housing.
  4.  
  5. Install and tighten the fasteners.
  6.  
  7. Fill the cooling system with approved antifreeze.
  8.  

Fox
  1. The thermostat is in the bottom of the water pump housing and the lower radiator hose connects to the thermostat housing. Place a large drain pan under the thermostat housing. On some models, it will be necessary to position the power steering pump aside.
  2.  



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Fig. If necessary, remove the power steering pump



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Fig. Hang the pump with a wire and position it aside

  1. Remove the radiator cap and drain the cooling system.
  2.  
  3. Loosen one bolt at a time until coolant begins to flow. Allow this residual coolant to drain into a pan.
  4.  



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Fig. The thermostat housing is secured by two bolts



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Fig. Slowly pull the housing away from the engine. Stand back and allow any residual coolant to drain into a pan

  1. Remove both bolts, then remove the thermostat. It's not necessary to disconnect the radiator hose.
  2.  



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Fig. Pull the thermostat out of the water pump housing. Once again, stand back to allow any left over coolant to drain

  1. Discard the O-ring on the thermostat housing.
  2.  



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Fig. Always replace the O-ring on the thermostat housing

To install:

  1. Place the thermostat into the water pump housing, then install the new O-ring. Install the housing and torque the bolts to 7 ft. lbs. (10 Nm).
  2.  
  3. Fill the cooling system. Start the engine and check for leaks.
  4.  

 
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