1.9Cdti Thermostat removal

[Cruize]

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?

[alcutler]

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.

[alcutler]

Does this make it a bit clearer -

[Cruize]

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.

[alcutler]

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

[Mark-R]

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.

[Damo77]

I had to cut that bracket off to do the stat on my 120.

May I be so bold as to ask what method & tools you used to cut said bracket off the EGR cooler gents

I am looking to replace my Thermostat in the near future but trying to get my head round the removal of this bracket before pressing on with the job

Was thinking of getting my Die grinder out with some Sheet Metal Cutting discs (As below) but I doubt I will be able to get close enough to the bracket due to thermostat and cooler piping being in the way

cut_off_wheel.jpg

vectrathermostat.jpg

My next thought was to bring my 90deg windy from work and make several drill holes in a line and try join them up to cut the bracket but not sure if that is the most logical solution, are there any other methods that can be used????

1121.jpg

Look forward to any suggestions gents

Many thanks in advance
Damo

[C-Owner]

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

[C-Owner]

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.

[alcutler]

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