Date:         Thu, 22 Feb 2007 16:17:03 -0500
Reply-To:     Roger Sisler <rogersisler2000@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Roger Sisler <rogersisler2000@YAHOO.COM>
Subject:      Re: help with '83.5 Westy thermostat housing

The thermistat housing is an Achilies heal for the 1.9. If a 1.9 is low
mileage and 23 or so years old,the water pump probably has not been
replaced.Bad news!!  The steel bolts have most likely fused to the
aluminum from corrosion of dissimilar metals.VW put in 8.8 grade bolts all
around, but they will snap off with ease. I have never seen a 1.9
thermistat housing come off, and be completely disassembled, without at
least one bolt snapping.I had a low mileage(62K)1.9 where all the bolts
snapped. Every one.After the first two snapped,it was a game.Even the M8
through bolts that hold the housing to the water pump snapped.

If you can remove your t-housing from the engine, do not remove the bolts
that attach the steel piece for the short hose. No No!!  Leave that gasket
alone.

The two bolts that attach the lower housing where the thermistat is,
probably cannot be left alone. The thermistat occasionally needs to be
removed. Better do it now.Perhaps the thermistat was removed and antiseize
compound was used on these bolts,sometime in the past. That is good.

If you can remove the housing from the engine, and thermistat from the
housing, you are most likely good to go.Many times there is corrosing and
sever pitting where the housing mates to the water pump. JB weld stick
will fix this up very well.JB weld stick will also fix the  aluminum O-
ring seat on the inside of the housing, and any pitting(almost no matter
how deep it is)on the lower thermistat cover where the hose attaches.I do
not know if a rubber O-ring can replace the plastic O-ring for the water
cross over pipe. I think BD has plastic o-rings.

Drilling out snapped off bolts is not easy to do.Maybe you can save your
old housing.Like most medical conditions, prevention is better than the
treatments they may have.

I sold a reconditioned thermistat housing last summer for $85, on
ebay.Absolutely gorgeous!!!It sold in two days.It was wire wheeled clean
of all corrosion. I repanted it with POR15(clear and sterling silver), and
included new gaskets,a packet of antiseize compound, and 10.9 grade bolts
all over. I thought it was priced too high, but I got many requests for
this housing after it sold.Did I have another, folks were asking?

Next one is gonna be $99, or more.If I can find one.That is the
problem.They are so corroded to the water pump that I cant get one off
without damaging it beyond my capacity to repair it. I guess they all have
been low mileage housings, so far. What you want is a high mileage
housing, where the housing has been removed several times.The housing I
successfully repaired was a high mileage housing.$80 bucks sounds high for
the cover.I have several of those thermistat covers that survived the
housing removal.The housing,proper was destroyed.

 Use a drill and bit to remove the crust in the through bolt holes.It is
amazing how much white stuff will drill out(not alunminum). Use antizeize
compound all over. Leave the gasket for the short hose alone.The housing
can be removed with heat from a torch.I think this can only be used after
the housing has been removed from the vehicle. I have a torch now and I
heat the aluminum up and ease the bolts out.I can do all of them this
way,now. All may break otherwise.

This is why any 1.9 thermistat housing ,in good ,disassembled condition ,
will cost plenty.Do not buy a housing that has not been disassembled.At
least the thermistat cover needs to be removed. If you do buy a
undissassembled housing, you can expect to break off the bolts that remain
unfasened,if you do not use heat( you may have to pay somebody to do this-
not cheap or garuanteed).Once again, you can leave the steel flange for
the short hose, alone, with success.Without using heat, perhaps radiater
stop leak is best to fix this gasket if it ever decides to leaks. Get a
new plastic o-ring if it is really bad.If you want to reuse it, coat it
with RTV and then reinstall.It will probably be ok.

Your  best source for a thermistat housing may be one that was surplus
when a 1.9 was removed for a Subaru engine transplant.Anyone got one for
this guy? If you can get one that is off the engine, but low mileage, take
it to a shop with a torch. High mileage housings may respond to a wrench
on the bolts ,with extreem care.If you think one is twisting off,stop!!!
Liquid wrench wont really help in this case. Good luck!!