Greg Campbell, Seattle, USA, gregc@eskimo.com

In the Bently manual there's a picture of the housing on page 19.17. The picture is pretty good at showing what's in the assembly. But here's what it doesn't tell you.

1) Location It's located on the top right side of the engine, under the distributor cap. Follow the radiator hoses right to it.

2) How to get to the lower part, where the thermostat is located The 5mm hex bolts are too close to the transmission to remove. You have to take out the whole assembly, then remove the lower part to expose the thermostat

3) How many hoses, and other things have to come off before the housing. I removed the 2 radiator hoses. I removed the plastic cover on the top of the radiator, & the fan's electric plug for better access. I also removed the plastic cover over the 3 sensor connections on the housing. Tug & pull it toward the battery. I removed the cover for the coolant run-on (Bently diagram item #7 pg 19.17) located on the lower front of the housing.

4) How many & where are the bolts to remove the thermostat housing? The Bently shows only 1, but there are three. All 5mm hex drive. The first is in the picture in the Bently (pg19.17) The second is below the one displayed in the manual. The third is at the rear of the housing. It sits back, tucked in the a hole behind the housing. It's pretty tough to get at. The three bolts make a triangle of sorts. I had to run to Sears & buy a 5mm hex drive & a 6'' socket extension to get at it.

Over all, the disassembly process was fairly difficult. The assembly process went very smoothly. Now that I've done all the "discovery", the job would fairly easy to repeat.

Things to buy before you start:

1. The thermostat
2. 5mm Hex Drive
3. 6'' socket extension
4. 1 Gallon of VW coolant.
5. Rubber "O" rings. The Bently says there are 2 to replace. The one on the thermostat was in really good shape. The one between the housing and the block was pretty bad off. I cleaned it up, soaked it in oil, the put some gasket goop in with it. No leaks so far.

I did get some WaterWetter but haven't put it in. Winter is coming & Washington stays pretty cool. My temps are back to normal, Coolant=the thick mark between 160 & 230, occasionally it goes up to 230 but never for long. Oil, ususally 212. When driving hard, it can go up to 230, 240ish.

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