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Thread: cdti 120 Thermostat removal

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    Default cdti 120 Thermostat removal

    Hi all

    Does anybody know the easiest way of changing the stat housing on a face lift 120 cdti. Started at the weekend and then gave up as it was starting to look like a bigger job than first thought.

    Thanks
    Dean

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    Regular Member barney490's Avatar
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    Sorry to say the stat on 120 is a lil pig to do. The egr cooler needs to be removed to allow access to one of the stat bolts. As i recall there are two bolts around the back of the block that hold the egr cooler on. I have heard that people also remove the vac pump, to gain better access to the thermostat, but get a new gasket for this from the dealers, dont use the old one.

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    Regular Member alcutler's Avatar
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    Vehicle : vectra c 1.9cdti 120 estate

    Trim : design



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    Hi, He's right it is a right pig to do- the problem is the bracket that holds the stainless steel cooler, and is bolted to the engine through the lower hole of the thermostat housing - here is a picture http://imageshack.us/photo/my-images...medeargod.jpg/
    I have cut this bracket off using a small cut off air tool - the cooler is still solid and replacing the thermostat is a doddle without the bracket there.

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    Regular Member alcutler's Avatar
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    Vehicle : vectra c 1.9cdti 120 estate

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    Thinking about it the way I did it was - the lower bolt has a smaller threaded stud that holds the bracket in place - I prised the bracket away from larger head of this bolt and then hacksawed through the stud as close as possible to the head - I then unbolted the lower bolt which forced the bracket to bend slightly, got a set of grips on it and bent it away from the bolt head which gave me enough room to unscrew all the threads out of the block but the bolt was prevented from coming right out by the ******* bracket. Removed the top bolt from the housing which allowed me to slide the thermostat up and over the bracket. Once the thermostat is removed you have plenty of space to cut the bracket off. You will struggle with a hacksaw - I used a small angle grinder. Don't worry about removing the bracket as the cooler is still rock solid. Before doing this I undid every bolt I could find that was securing the cooler but it would not budge an inch. Did mine a couple of years ago and not had any problems, other than the thermostat failed agian and I had to change it again but this time with no bracket it was a piece of cake. Hope this helps and good luck

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    Pig of a job as above undo the 2 bolts on back of block 13mm socket with extension get a bar between thermostat and cooler bracket and prize outward it will give you enough room to get bottom bolt out of thermostat with a spanner. Once thermostat is out cut bracket off with small angle grinder.

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    Regular Member alcutler's Avatar
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    Quote Originally Posted by shayom View Post
    Pig of a job as above undo the 2 bolts on back of block 13mm socket with extension get a bar between thermostat and cooler bracket and prize outward it will give you enough room to get bottom bolt out of thermostat with a spanner. Once thermostat is out cut bracket off with small angle grinder.
    Well done -We did try to tell you - absolute crap design - good news is - its a lot easier to do next time

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    Regular Member alcutler's Avatar
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    Vehicle : vectra c 1.9cdti 120 estate

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    Here's a clearer picture of the offending bracket that might help someone attempting the job




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