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Thread: Modifying Thermostats

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    Modifying Thermostats

    I have had a small overheating issue with my 300TDI. I have heard that drilling two 1/8” holes in the hem (top and bottom) of the thermostat allows air to pass through these holes and a small amount of fluid. I Googled the procedure, but anyone can make a YouTube video.

    Interested to hear if anyone has tried this modification on a tdi thermostat?

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    Most thermostats I've purchased over the years have had a hole about 3mm dia in the hem to, I assume, help bleed the system. Some have had a nylon jiggler in the hole.
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    Quote Originally Posted by Kidbeen View Post
    I have had a small overheating issue with my 300TDI. I have heard that drilling two 1/8” holes in the hem (top and bottom) of the thermostat allows air to pass through these holes and a small amount of fluid. I Googled the procedure, but anyone can make a YouTube video.

    Interested to hear if anyone has tried this modification on a tdi thermostat?
    Waste of time, the bleed hose assembly to the radiator and header tank does that job already. Pull off the bleeder assembly and make sure the small jet from the thermostat housing isn't blocked with crud.

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    Quote Originally Posted by Kidbeen View Post
    I have had a small overheating issue with my 300TDI. I have heard that drilling two 1/8” holes in the hem (top and bottom) of the thermostat allows air to pass through these holes and a small amount of fluid. I Googled the procedure, but anyone can make a YouTube video.

    Interested to hear if anyone has tried this modification on a tdi thermostat?
    Find the source of your over heating first no 1
    Why modify the factory set up as there are plenty of standard Tdi`s running around with out overheating issues .
    Checked your Viscous fan is working correctly ect

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    Also, I am interested to know the affect of having the aircon on going up steep inclines and its relationship to overheating. Is it the extra pulley work on the motor or is it the condenser that is trying to cool the hot air coming from air conditioning compressor that is interfering with cooling the radiator, as the air has to move through the condenser before reaching the radiator. I also wonder what percentage of air those condensers actually block.

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    I’d say you have other issues......I’d be leaving the thermostat alone

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    Quote Originally Posted by Kidbeen View Post
    Also, I am interested to know the affect of having the aircon on going up steep inclines and its relationship to overheating. Is it the extra pulley work on the motor or is it the condenser that is trying to cool the hot air coming from air conditioning compressor that is interfering with cooling the radiator, as the air has to move through the condenser before reaching the radiator. I also wonder what percentage of air those condensers actually block.
    You have other issues.

    Stop trying to blame the factory setup !
    You need to eliminate Blocked radiator , Stuck thermostat ,Viscous fan and god forbid Head or Head gasket ect.
    This is before you start your best Professor Sumner Miller impressions

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    Why is it so?

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    To be honest Rangieman, I thought it was a fair question. I have read on this AULRO site about turning off air conditioning when the motor is getting hot. Just wanted to know the science behind it. Perhaps someone will tell me.

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    Quote Originally Posted by Kidbeen View Post
    To be honest Rangieman, I thought it was a fair question. I have read on this AULRO site about turning off air conditioning when the motor is getting hot. Just wanted to know the science behind it. Perhaps someone will tell me.
    Yes it's because of the increased load of the engine and extra heat from the condenser, generally you overheat because your condenser fan isn't working cooling the condenser while idle in traffic. You can get away with it on the freeway if your viscous is working and it's not too hot out.
    Cheers Jim

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