1.4BBY the tale of two thermostats

[a2a]

Hi A2A, just double checking that you've removed the self tapper that fixes into the housing through a tab on the metal tube that connects between EGR and Throttle Body ... I'm sure you have.
Definitely a push fit and sealed with a square section O ring into the water pump housing ... it's possibly never been removed before but it's only the rubber seal that's holding it, should give way.
I replaced the tube (14) along with the housing for peace of mind but sounds like you might destroy your seal on removal.
Have you tried WD40 ...maybe help to free it up?

Thanks Tom, that's good to know.
Will get some WD40 in there and keep pulling!
Have ordered two o-rings...£20 the pair

 

[Tomscar]

Thanks Tom, that's good to know.
Will get some WD40 in there and keep pulling!
Have ordered two o-rings...£20 the pair

You'll get there and probably loose some skin when it gives in.
I don't think I paid £20 for the coolant pipe complete with seals!
Were you able to free the housing without removing the EGR pipe?

 

[a2a]

DONE IT! The death pipe is off!

Approaching it with a fresh mind this morning I:

• Got some light in there (wedged a floodlamp in the engine bay)
• Got the car higher up for better access - it's easier to see the pipe looking from behind the subframe, rather than up through where the driveshafts are
• Removed the PCV so I had better access to the stuck death pipe
• Sprayed WD40 where the pipe met the water pump

Once I could get my hands onto the pipe properly I could wiggle it about. Now I was underneath, it was apparent that all the wiggling, twisting, and pulling of the thermostat housing was just causing movement at the housing end of the pipe, but having no effect on the water pump end at all.

It took a few goes with increasingly colourful language and effort, but in the end I swore at it and shoved as hard as I could, and it gave way, dumping half a pint of coolant in my ear/mouth/back of my neck Having some grippy mechanic's gloves on helped for sure, along with the WD40.

I will reassemble once I have the o-rings from Audi. I'll use a smear of silicone grease to aid any future disassembly and help keep it water tight.

As a reminder, I'm replacing the housing because mine's stripped. At some point somebody used the wrong screws when replacing the thermostat cover so when I swapped the thermostat myself, it wouldn't tighten up and hold water.

TOM, ANDY - Thanks for your help!

 

[Tomscar]

DONE IT! The death pipe is off!

Approaching it with a fresh mind this morning I:

• Got some light in there (wedged a floodlamp in the engine bay)
• Got the car higher up for better access - it's easier to see the pipe looking from behind the subframe, rather than up through where the driveshafts are
• Removed the PCV so I had better access to the stuck death pipe
• Sprayed WD40 where the pipe met the water pump

Once I could get my hands onto the pipe properly I could wiggle it about. Now I was underneath, it was apparent that all the wiggling, twisting, and pulling of the thermostat housing was just causing movement at the housing end of the pipe, but having no effect on the water pump end at all.

It took a few goes with increasingly colourful language and effort, but in the end I swore at it and shoved as hard as I could, and it gave way, dumping half a pint of coolant in my ear/mouth/back of my neck Having some grippy mechanic's gloves on helped for sure, along with the WD40.

I will reassemble once I have the o-rings from Audi. I'll use a smear of silicone grease to aid any future disassembly and help keep it water tight.

As a reminder, I'm replacing the housing because mine's stripped. At some point somebody used the wrong screws when replacing the thermostat cover so when I swapped the thermostat myself, it wouldn't tighten up and hold water.

TOM, ANDY - Thanks for your help!

Great job A2A, you got there ... have you decided which thermostat you're using yet?

 

[a2a]

Great job A2A, you got there ... have you decided which thermostat you're using yet?

The black cartridge style 87°C one, as I believe it's the right temperature for the car in the UK, regardless of whether it's a metal or plastic style. My car ran too cool with the 82°C one (although it had been replaced at some point, I suspect it was defective).

Interestingly I tested 4 different stats in a pan of water. 3 of them, all rated the same temperature, behaved very differently!

 

[Tomscar]

The black cartridge style 87°C one, as I believe it's the right temperature for the car in the UK, regardless of whether it's a metal or plastic style. My car ran too cool with the 82°C one (although it had been replaced at some point, I suspect it was defective).

Interestingly I tested 4 different stats in a pan of water. 3 of them, all rated the same temperature, behaved very differently!

I had exactly the same experience with very little heat from the vents using the lower temperature thermostat ... the 87°C plastic one fixed it ... interesting experiment testing in a pan of water though