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Thread: 1.9Cdti Thermostat removal

  1. #1
    Regular Member Cruize's Avatar
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    Default 1.9Cdti Thermostat removal

    Having a hell of a problem getting my stat off.
    Followed the guide which is spot on if for the fact it appears someone has been at this engine previously.

    On the stat itself the top bolt was a torx head instead of a 13mm, ok not a problem but then we go underneath and there is a nut and stud??

    Put the phone under and got a good snap of it and there is a stud coming from the bottom hole and there is a plate over it which appears to attach to part of the EGR system just underneath. The plate is wealded to the EGR system which is rigid and wont budge, so it seems I have to remove part of the EGR system to get the stat off... Cant be right...

    Here are some pics? What does everyone think?


  2. #2
    Regular Member alcutler's Avatar
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    Vehicle : vectra c 1.9cdti 120 estate

    Trim : design



    Default

    Take it it's the 120? - it's a right pig of a job - when I did mine I cut that bracket off the intercooler as I could not remove the body itself even though I had removed every bolt and connection to it - it was still solid - access is your big problem - you need to cut that stud off as close to the bracket as possible, there is a hexagonal bolt head behind the bracket, and then undo the pipe clamp on the intercooler that you can see on the left side of your picture. You then have to lever the main body away from the block and you should just have enough space to completely undo the bottom bolt although not remove it . With the upper bolt removed you should be able to slide the stat housing up from behind the bracket and out of the car. With the stat out the way you have access to the bracket - cut it off - it doesn't need to be there as the intercooler body is rock solid even without it and reassembly is simple with it out of the way. Good luck with it.

  3. #3
    Regular Member alcutler's Avatar
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    Vehicle : vectra c 1.9cdti 120 estate

    Trim : design



    Default

    Does this make it a bit clearer -

  4. #4
    Regular Member Cruize's Avatar
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    Default

    Yeah its the 120.
    Who designs these things. I mean seriously lol... Thanks for that mate. Makes it a bit clearer. I thought it may be hiding behind the bracket but couldnt find any mention of it so just assumed some mungo had put a stud in there.

  5. #5
    Regular Member alcutler's Avatar
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    Vehicle : vectra c 1.9cdti 120 estate

    Trim : design



    Default

    Fiat - I suppose - no that's the correct fitting it's a bolt with a stud attached - remove the stud and it becomes a normal bolt

  6. #6
    Regular Member Mark-R's Avatar
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    Vehicle : GSI

    Trim : (vxr/irmy)

    Engine : 3.2 v6

    Year : 2004

    Default

    Yeah when did mine i had to cut that bracket off too what a pain in the but to do the stat on a 120.

  7. #7
    Regular Member C-Owner's Avatar
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    Default

    I have modified these brackets on the JTD's and Z19dt's for future works.

    The bracket just needs a small piece removed so it can be secured with the nut after the thermostats been changed.

    I use a washer with a nylock nut on refitting.


    Disclaimer.
    Photoshopped image, not an actual original image
    Last edited by C-Owner; 9th December 2012 at 20:50.

  8. #8
    Regular Member C-Owner's Avatar
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    Default

    Too late to edit original post.

    Just to add I dont recommend cutting bolts and brackets off completely.

    The brackets secured that way for a good reason , vibration and dampening of the inter-cooler unit.

    Just saying no offence meant to anyone.


  9. #9
    Regular Member alcutler's Avatar
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    Vehicle : vectra c 1.9cdti 120 estate

    Trim : design



    Default

    Removed the bracket on mine over 2 years ago and never had a problem - can't see how the v cut in the top of the bracket helps as it is still in the way of removing the lower bolt

  10. #10
    Regular Member john norris's Avatar
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    Default

    just done my 150 the other day looking at the pic im glad I dont have the 120 begest pain for me was getting a hose clip off that wouldn't budge

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