200tdi theromostat housing removal - Defender Source
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  #1  
Old October 3rd, 2013, 10:16 PM
kjva
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Ken Jackson
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200tdi theromostat housing removal

Have a 200tdi with a stuck thermostat. When removing the housing the bolts sheared off and will need to be drilled out.
To remove the housing the head should be removed as the engine has just been rebuilt I am reluctant to do that.
Looking at other forums the bolts are 2mm lo long. I was thinking of cutting them getting two new bolts and milling 2mm off them.
Can anyone see a downside with this.
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  #2  
Old October 3rd, 2013, 10:26 PM
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Quote:
Originally Posted by kjva View Post
Have a 200tdi with a stuck thermostat. When removing the housing the bolts sheared off and will need to be drilled out.
To remove the housing the head should be removed as the engine has just been rebuilt I am reluctant to do that.
Looking at other forums the bolts are 2mm lo long. I was thinking of cutting them getting two new bolts and milling 2mm off them.
Can anyone see a downside with this.
All three bolts sheared? Can you use sone heat and a lefty drill bit to try and remove what's left of the bolts? If the bolts are all sheared then doesn't the housing come right off ?
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  #3  
Old October 3rd, 2013, 11:13 PM
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Are you sure the head needs to come off?
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Old October 3rd, 2013, 11:47 PM
kjva
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Ken Jackson
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Quote:
Originally Posted by Ren Ching View Post
All three bolts sheared? Can you use sone heat and a lefty drill bit to try and remove what's left of the bolts? If the bolts are all sheared then doesn't the housing come right off ?
The bolts holding down the top of the housing sheared they were 10mm heads.
By the look of them they had bee on there a very long time.
I would have thought when the engine was rebuilt the thermostat was checked.
They will need to be drilled out I could do it in situ but is better if I can get the housing off

------ Follow up post added October 3rd, 2013 11:50 PM ------

Quote:
Originally Posted by Red90 View Post
Are you sure the head needs to come off?

Yes I looked on the UK forums and several commented what a bad design it was.
One guy milled off about one mm on the timing cover and one mm off the bolts and they would fit.
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Old October 4th, 2013, 08:15 AM
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Ren Ching
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Can't you unbolt the housing from the head? I recommend using extreme caution/patience/PB blaster and tap the heads with a small hammer to loosen them up. Oh and heat too.
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Present:
1960 SII 109"- "Red Square"
1984 90 Tdi- "Yamelo"
1988 RRC- "Chewbacca"
1987 RRC- "Chewy 2"
2008 RRS SC- "The Supersofa"

Past:
1959 SII 88"- "The Little Green Beastie" last seen in NY
1972 SIII 88"- "GreenHELL" now in NC
1988 90 "Eric the Half a Bee" half a truck, sold for parts
1991 RRC- never got a name- long since recycled
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  #6  
Old October 4th, 2013, 08:47 AM
kjva
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Ken Jackson
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Quote:
Originally Posted by Ren Ching View Post
Can't you unbolt the housing from the head? I recommend using extreme caution/patience/PB blaster and tap the heads with a small hammer to loosen them up. Oh and heat too.
The top bolt yes, the bottom two hit the timing cover and can not be removed.
That is why I am thinking about cutting them and milling 2mm off the new bolts.
One post on a UK forum suggested milling 1mm off the timing cover and 1mm off the bolt heads.
Another post the guy had rebuilt the motor and fitted the head and omitted the thermostat housing to find it could not be fitted with the head in place.
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Old October 23rd, 2013, 03:16 PM
kjva
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Ken Jackson
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Cut off the two lower bolts found some slightly shorter ones in NAPA had to grind a little off the heads off them to make it work.
For the top cover found the right bolts in Tractor Supply.
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