This video captured the steps requires to replace the engine thermostat housing and the tools you will need to perform this task.

Time : I’ve spent about 5 hrs with Engine oil change and clean any parts I removed during the process. Some local garage shop said this thermostat replacement is between 3-4 hrs job. I personally think it is possible to change thermostat in 3 hrs when there is no issue with disassembly.

Parts cost for my project:
1/ thermostat- after market part - $80.00
2/ VW G13 coolant - $25.00 (dealer item)
3/ coolant temp sensor, O-ring and clip - $50.00 ( dealer item)
4/ engine oil filter cartridge - $22.00 (dealer item)

Challenges:
I lost about 1 hr trying to disconnect large coolant hose adapter from thermostat housing. The o-ring bonded tight to thermostat at the hose connection. I’ve soaked with penetration oil for an hour and keep wiggle it till it got it move. I also used paint stir wooden stick and placed at the thermostat housing at the hose connector and gently tap to break loose. It works for me once the penetration oil has it chance to do its magic.

Alternator removal took about 40 min. Alternator bushing need to be pushed out for ease of reinstallation later (see my video - VW EOS alternator removal)

Tools:
M5 torque bit
T27 torque bit
13 mm wrench and socket
Belt removal tool
36 mm socket to remove engine oil filter
10 mm socket
Various extension and 1/4 “ ratchet
Hose clamp pliers
Pick to remove electrical connector
Silicon grease to apply on all o-ring

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