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VW MK4 TDI 205 F Thermostat

This document provides instructions for modifying a stock 1.9L TDI (ALH) thermostat to open at 205° F. The instructions involve using a 1994 Ford 7.3 Turbo Diesel thermostat rated for 205° F and transferring its bypass portion to the stock ALH thermostat housing using simple hand tools. Key steps include using metal strips to support the thermostat while gently tapping out the original bypass piece, pressing the 205° F bypass piece into the stock housing while ensuring proper alignment and match of the original top-bottom plate distance. Following these steps produces a hybrid higher temperature thermostat without complex modification.

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David Neiferd
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309 views3 pages

VW MK4 TDI 205 F Thermostat

This document provides instructions for modifying a stock 1.9L TDI (ALH) thermostat to open at 205° F. The instructions involve using a 1994 Ford 7.3 Turbo Diesel thermostat rated for 205° F and transferring its bypass portion to the stock ALH thermostat housing using simple hand tools. Key steps include using metal strips to support the thermostat while gently tapping out the original bypass piece, pressing the 205° F bypass piece into the stock housing while ensuring proper alignment and match of the original top-bottom plate distance. Following these steps produces a hybrid higher temperature thermostat without complex modification.

Uploaded by

David Neiferd
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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205 F Thermostat

Inventor: josh8loop
Instructions: josh8loop
Write-Up: JohnDN (ALL credit goes to josh8loop, I simply took his instructions and YouTube video and
made this write-up from them).
http://forums.tdiclub.com/showthread.php?t=306799

Required Parts
Stock 1.9L TDI (ALH) Thermostat
1994 Ford 7.3 Turbo Diesel (VIN Code F) Thermostat (Stant # 14252)

Required Tools
Two Metal Strips (Supports)
1/4 -20 Bolt
Hammer
1/2 ID Metal Pipe (with notch removed)
Vise

Step 1: For disassembly acquire the stock ALH thermostat
(Stant brand), a 1/4-20 bolt, a hammer, and two metal strips
with a notch gut out to fit around the bottom of the
thermostat.

Step 2: Measure the distance between the top plate and the
bottom plate. We will use this measurement when reinstalling
the bypass to the 205 F thermostat.

Step 3a: The metal bracket will be used as a support
immediately below the bottom plate as shown here.

Step 3b: The support will rest against the backside of the
bottom plate when placed properly. Place the second support
on the opposite so fully support the thermostat.

Step 4: Place the supports over a face and place the 1/4-20 bolt
through the center of the thermostat. Be prepared to catch the
thermostat or place something soft under it to catch it.

Step 5: Gently tap the bolt with the hammer to remove the
bypass portion of the thermostat.

Step 6: The thermostat should now be separated into two
pieces as shown.

Step 7: Acquire the required materials for assembly of the new
hybrid thermostat.
205 F Thermostat (Stant #14252)
Bypass Piece from Stock Thermostat
1/2" Pipe with notch removed to fit over thermosat

Step 8: Place the support pipe over the top of the thermostat.
It should not contact the support bridge at the very top of the
thermostat. The pipe should rest against the largest metal
portion on the interior of the thermostat.

Step 9: Lightly lubricate the bypass piece and press it on gently
with your hand. Ensure the piece is aligned with the rest of the
thermostat as much as possible.

Step 10: Place the thermostat in the vise and slowly turn the
vise to press the bypass piece on. Ensure all pieces of the
thermostat remain aligned during this process. DO NOT PRESS
THE BYPASS ALL THE WAY ON YET.

Step 11: As you slowly press the bypass piece on the
thermostat take measurements of the distance between the
top and bottom plate. The distance should be set the same as
the measurement taken in step 2. Once the piece is pressed on
and this distance is correct, you are finished.

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