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How to Change a Thermostat in a Volkswagen Touareg 4.2

by Lisa Wampler

Many people will take their Volkswagen Touareg 4.2 to a dealer when small items like the thermostat fails. They do this because they think the average person cannot work on them because foreign engines tend to be slightly different than American-built engines. However, with the Touareg, this is not the case. It's perfectly possible to swap out that broken thermostat with a new one with just a few basic hand tools and a few dollars in parts.

Locate the thermostat cover where the top radiator hose connects to the top of the engine. The metal part that the hose connects to is the thermostat cover; this cover is connected to the Touareg's air/coolant intake manifold.

Remove the bolts that hold the thermostat cover onto the the intake manifold with a 10 mm wrench then pull the cover off of the intake manifold. This will expose the mechanical thermostat. Push the radiator hose off to the side so you can access the thermostat easily.

Pull the old thermostat out of the intake manifold and replace it with a new OEM (original equipment manufacturer) thermostat. The end marked "Top" must stick out of the engine. Thermostats are available at most auto parts retailers or Volkswagen dealerships.

Remove the carbon gasket sandwiched between the cover and the intake manifold and replace it with a new OEM gasket. These are available at most auto parts retailers or Volkswagen dealerships.

Bolt the thermostat cover back into place. Do not overtighten the thermostat cover as it's possible to crack it. If the cover does crack, it should be replaced, not repaired.

Tip

  • It's possible that the radiator hose will have some radiator fluid in it. Forcing the hose into a vertical position will cause the fluid to flow back into the radiator. This will prevent radiator fluid from getting onto the engine.

Items you will need

About the Author

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  • radiator humor image by John Sfondilias from Fotolia.com