In a message dated 7/31/2001 7:01:35 PM Pacific Daylight Time,
dbeierl@ATTGLOBAL.NET writes:

Some people have been unable to do it but I
>  don't know whether that's a difference in engines or in people's spatial
>  abilities -- I've always been the guy who could get the refrigerator down
>  the apartment stairs.

I'd like to believe it's a difference in engines and possibly approach. For
example I replaced the thermostat in my 83.5 1.9 liter without having to move
the refirgerator at all. ;)

Here's what I encountered: The lower thermostat housing would not clear the
exhaust manifold when I tried to remove it. I only needed a couple more
millimmeters to be able to get the lower themostat housing off but to the
best of my ability, no go.I ended up taking the entire thermostat housing off
the side of the water pump. Mine was "welded" to the water pump by the DPO
with some sort of epoxy and the whole thing wouldn't come apart. In fact it's
still glued together in my garage. But barring an overzealous install by the
last guy the thermostat housing should come out relatively eazy if it comes
to that.

My guess is the difference in engines has to do with the exhaust manifolds.
It seems my exhaust is closer to the lower themostat housing than some. I'll
double check in a few weeks as my bus is running a bit cool and a series of
tests will soon involve checking the thermostat.

One more thing. The upper thermostat housing is $225 from VW and not
available any where else. So do your best not to damage it. And pay attention
and abide by the torques Bentley assignes for the thermostat housing and the
water pump if it goes that far.

I'm guessing it's a good idea to check the new thermostat before you put it
in. I think you can do it on the stovetop with a candy thermometer and the
themostat submerged in water to see when it opens. I've never tested a
thermostat but I wish I had to save pulling this one out. Hopefully another
listee will chime in as to whether this is a valid test method.

Having said all that hopefully the lower thermostat housing will clear your
exhaust. And truthfully either way it's not that tough a job as long as
things aren't epoxied together.

Good luck,
Jeff
83.5 Westy
LA,CA