Thermostat removal in JX - How to remove alternator

[noggintom]

Hi All,

I have been doing some work on my diesel JX's cooling system to stop leaks etc.and to change a stuck thermostat. I have removed the hose to the plastic thermostat housing but cannot removing the housing as one of the two nuts is impossible to get at. Can some one confirm that I need to remove the alternator and it's connections to the waterpump to get access? If so how do I do this? I have slackend the alternator tensioning nut and pushed the alternator down but I cannot move it enough to get the belt off, am I missing something?

In case it is relevent I have a late model JX with Power Steering so there are a few more pipes and belts here than normal.

The good news is that I managed to change the temp sensors, the cracked header tank and the leaking switch to the heater under the back seat. The van is currently sitting 'dead' with the lost coolant in a bucket and looking rather sad!

Thanks in advance.

[noggintom]

Hello All,

An update: After studying the manuals and having a poke around the engine bay I think it is the power steering pump bracket that is preventing access to the thermostat housing.

So, the current problem is getting the alternator out so I can get to this. I have slackened the alternator adjuster and removed the long bolt holding the alternator on the other side. The alternator only moves down around 10mm and I cannot remove the belt. The left hand side of the alternator is still connected even though I have removed the nut??

Do I have to slacken the power steering pump tensioner to get enough play to get the alternator belt off? Or, should I try to stretch the belt over (looks difficult to get enough stretch)?

Power steering is great....however....

Thanks all in advance,

Tom.

[pauly8888]

I found that if I lay on the floor beneath the van, I could see both bolts holding the thermostat housing in place.
Haven't got PS though, so don't know if this makes any difference.
Have buggered about with my thermostat a few times lately and found no need to remove the alternator.

[ringo]

Same as Pauly, ive never had to remove the alternator to take the thermostat out. And again, ive never had power steering.

You may need to give the alternator some pressure to pop it out if you have taken all the bolts out and it still doesnt budge. I found so many different belt sizes that some i had to physically take the alternator out to take the belt off and refit it.

Im struggling to think how anything could be in the way of the thermostat - a photo would help if you are still struggling.

Good luck,

Ringo

[noggintom]

Thanks guys,

I'll try to take a photo after work tomorrow. I think this is a power steering issue... I think the power steering pump bracket is covering one of the screws for the thermostat housing. I've had the van up on a lift at our work motor club and am pretty sure one nut is covered.

I will spend some more time investigating tomorrow and report back.

Tom (frustrated!).

[noggintom]

Hi all,

A quick update... It is the the power steering pump bracket that is in the way of one of the thermostat housing bolts. There is a small gap between the bracket and the housing but my spanner is too thick to get through (and I doubt there is enough space to withdraw the bolt anyhow).

So, after two hours trying to remove the bracket I am still stuck - the bolts attaching the bracket to the engine are stuck fast. I need to get some better tools to get them free/soak them for a few days first.

I took some photo's which I will post when I work out how to (is there a link with instructions? I cannot find anything by searching the forum). I will give an update when I get a bit further on with the job.

Thanks all,

Tom.

[noggintom]

Hi all,

Have not been on the forum for a while but thought i would post again on this as i eventually solved the problem! Hopefully helpful for someone else in the future.....

Basically, the PAS pump is mounted on a solid metal bracket that covers completely one of the bolts holding in the thermostat cover. The only way to get at the thermostat as far as I could see was to remove either the PAS pump and bracket or the alternator and water pump. Went for the water pump as access was easier.... So, belts off, alternator off, alternator mounting bracket off, water pump out (have to giggle it around a bit to get it free from the PAS pump bracket) and then to the thermostat. I decided to replace the water pump while i was there as I did not want to go back again!

The van is working fine again (thanks to the forum again for help on bleeding the coolant system). Happy days.

It does seem to me that the PAS system was shoe-horned in by VW where it fitted, with little care about maintenance by enthusiasts in the future!!!

Tom.