John Muir's Rabbit book for the complete idiot had a section on testing
thethermostat.  I think he called it a"thermostat cocktail" but I could bve
wrong.  Not sure if that book is still in print or not.  Mine's disapeared
since we sold the Rabbit in 89.
----- Original Message -----
From: "Jeffrey R" <Oxroad@AOL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, July 31, 2001 10:06 PM
Subject: Re: Thermostat install Question

> 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