Thermostat Replacement and Modification

Thermostat Replacement and modification http://www.dieselgiant.com/thermostatreplacementa...
Home Cars for sale Trucks for sale Where we are Links to other diesel sites About us Why diesel?
Diesel Videos How they work How they sound Video FAQ
Dodge Diesel Maintenance tips, parts and DIY DVD's VW Diesel Maintenance tips, parts and DIY DVD's
Mercedes Diesel Maintenance Page Mercedes Diesel parts for sale Testimonials Return Policy Email Us
Thermostat Replacement and modification
Home
Cars for sale
Trucks for sale
Where we are
Links to other diesel sites
About us
Why diesel?
How they work
How they sound
VW diesel maintenance
tips
Dodge diesel
maintenance tips
Bio diesel and WVO page
Mercedes Diesel parts for
sale
Mercedes diesel
maintenance tips
Testimonials
All parts used in these pictorials are available at the diesel parts for sale page
Thermostat replacement and modification
1 of 16 26/12/2023, 18:59
This pictorial has actually two purposes. The first is to show you how to change out your
coolant thermostat, and the second is to show you how to modify your new thermostat to
keep your temperatures down, if you are having that problem. The second part about
modification, is really a work around fix to a more difficult set of problems.
I have been repairing automobiles for almost 24 years. I have worked on just about
everything, including class 8 Semis, and I have never seen auto maker more plagued by
engine heat control problems than Mercedes. In my opinion the Mercedes have cooling
systems that are "just enough" when in "new" condition to get the job done. In all
fairness most of our beloved cars are 20 plus years old, and still do a good job, but the
cooling system is not transferring the heat from the engine to the air, with the best of
efficiency. You can change water pumps, radiators, fan clutches, t-stats, do a coolant
flush with acid, temp sensors, temp gauges, and on and on, till your are blue in the face.
Even after all that, SOME of the cars are just not going to run at the proper temp.
Overheating your car is a very bad thing. You can blow head gaskets, warp heads, seize
bearings, and a whole host of other problems. So thermostat modification is a good way
to make your car drivable again and give you peace of mind, if you have tried just about
everything else.
My recommendation on t-stat modification is that it is a LAST ditch approach. Replace or

repair all the items I listed a few lines above, before you do this modification. You may
find that one of them was your problem. Unfortunately none of them solve my problem,
so I did the t-stat modification.
I came up with this modification after racking my brain on how to get my ole '84 300d to
run between 82-90 degrees Celsius. After the modification, I could NOT get the car to
overheat even with the air on. The only draw back to this modification is that, the car
does take longer to get up to operating temp. So if you are in a cold climate I will make
some suggestions in the pictorial on what you can do.
Now understand that this modification is not a Mercedes fix, it is my fix. It keeps the car
running at the proper operating temp and that is what I am after. I weighed the trade off
of, taking out the engine, tearing it down, hot tanking it, rebuilding it, and then I might
have proper cooling temps. Instead I took a new t-stat and made my own set of
improvements which was a lot faster and MUCH cheaper. It works for me, you decide if
you need to do it.
So follow along as we replace and modify a coolant t-stat........
In the shop again as the "pictorial" mule, is the ole '79 300d. This is my daily driver and I
might say is the slowest car I have ever driven. This car also likes to run on the hot side,
like way hot even with the air off. So I will do a t-stat modification while we are changing
the old one out. Please do this when the car is cold, NOT HOT!
Safety and security tips:
Please remember to recycle all your used fluids at an appropriate recycling center.
Be mindful to not spill or splash fluids on yourself, others or the ground. Also as a
safety tip please remember anytime you are working on, around or under your car, to
wear safety glasses and secure the car with wheel stops and approved jack stands!
2 of 16 26/12/2023, 18:59
This is our work area and is called the thermostat housing. Inside the aluminum cover
contains the t-stat as we will call it, to save me from typing so much.
3 of 16 26/12/2023, 18:59
Simple selection of tools needed are 3/8 inch drive ratchet, 2 inch extension and 10mm
socket.
4 of 16 26/12/2023, 18:59
First remove the radiator cap. If you have a turbo diesel then your cap is on your
expansion tank located on the passenger fender well.
5 of 16 26/12/2023, 18:59
This is a good cap. Note that the rubber is NOT cracked or missing and is still very soft.
Replace your cap every time you do a coolant flush. (2 years)
6 of 16 26/12/2023, 18:59
Drain the radiator from the plastic plug on the bottom of the radiator. It is on the driver
side and has a slot for a large slotted screwdriver.
7 of 16 26/12/2023, 18:59
Yuck! This is a good time to get rid of the green anti freeze, do a flush and put in some
Mercedes coolant.
8 of 16 26/12/2023, 18:59
Be careful with the plastic plug, it will break if you are too aggressive with it. Make sure
the rubber seal in in good shape. If it looks suspect, just replace the whole thing.
9 of 16 26/12/2023, 18:59
Remove the 3 bolts that hold on the t-stat housing cover.....
10 of 16 26/12/2023, 18:59
....2nd bolt coming out......
11 of 16 26/12/2023, 18:59
...3rd bolt coming out
12 of 16 26/12/2023, 18:59
Here is where the rubber meets the road. Notice the proper orientation of the t-stat. The
disc on the end of the t-stat is there for a purpose and always goes toward the engine.
Make sure the new one goes in the same way. It is possible to install the t-stat in
backwards in these cars, and then you will have a hot problem.
13 of 16 26/12/2023, 18:59
The new t-stat and o ring. The part of the t-stat that you are looking at is the part that will
face the radiator. The disc is what it is resting on. Always use the new gasket that fits on
the outside of the t-stat. Do not reuse the old one it will probably leak. The other o ring
in the package is for the block to housing seal. Since we did not remove that part of the
housing, it will not be used.
14 of 16 26/12/2023, 18:59
Ok here is where we will go into the modification. I have already gotten another t-stat
ready that is modified. If you will notice the series of 3/16 inch holes that I drilled in the
rim. What this does, is allow some coolant flow in all conditions. It will not affect the
operation of the t-stat but, will increase the time of warm up on a cold day slightly. Since
the purpose of the t-stat is to remain closed when the engine is cold, and slowly open as
it hits a predetermined temp, this will delay the opening since cold radiator fluid is
trickling in. On a hot day it helps the t-stat equalize the temp using the entire capacity of
the radiator. I know that this modification flys in the face of logic, but I have done this on
several cars and I have ended the cooling problem. I also know that 5 holes is best for
summer use and 2-3 holes is better for winter use. I have experimented with many
different hole and temp factors and seem to have found a good blend for Atlanta's
climate.
If you live where its really cold then I would do 2 holes and start from there. In the dead
of winter 1 hole may even suffice. The key it to empower you to see what works best for
your car and climate. When it get really cold here, I will put in my 3 hole t-stat and use it
till late spring.
If you don't have a cooling problem then don't do this modification.
15 of 16 26/12/2023, 18:59
Install the t-stat back into the housing like in the earlier pic, install the 3 bolts with some
anti seize if you have it. Just tighten them down snug. Remember you are in an all
aluminum housing and it will not take too much torque to strip the bolts. Make sure that
you get the t-stat right side up. There may be an arrow or small jiggle hole that should
point to the sky when you install.
Refill with Mercedes coolant and the appropriate mix of water, run and check for leaks.
Now that was not so bad was it?
https://gwinnettlawns.com
16 of 16 26/12/2023, 18:59

Thermostat Replacement and Modification

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Thermostat Replacement and Modification

Uploaded by

Copyright:

Available Formats

Thermostat Replacement and modification http://www.dieselgiant.com/thermostatreplacementa...

Thermostat Replacement and modification

Thermostat replacement and modification

My recommendation on t-stat modification is that it is a LAST ditch approach. Replace or

So follow along as we replace and modify a coolant t-stat........

Safety and security tips:

Remove the 3 bolts that hold on the t-stat housing cover.....

....2nd bolt coming out......

...3rd bolt coming out

If you don't have a cooling problem then don't do this modification.

Now that was not so bad was it?

You might also like