How to carry out replacement: Thermostat 1.9 TDI Passat 3b5
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Change Passat 3b5 1.9 TDI Thermostat yourself – manuals and video tutorials

How to change engine thermostat on VW PASSAT Variant (3B5) – replacement guide

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When to replace the Thermostat on your VW PASSAT
Recommended replacement interval for the part category Engine thermostat : 50000 km
Important!
This replacement procedure can be used for:
VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 1.9 TDI 4motion, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.3 VR5 Syncro/4motion, VW PASSAT Variant (3B5) 1.9 TDI Syncro/4motion, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.3 VR5 … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Thermostat for PASSAT Variant (3B5) and other VW models
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Tools
Replacement: engine thermostat – VW PASSAT Variant (3B5). Tools you might need:
Torque wrench
Drive socket # 7
Drive socket # 10
Drive socket # 13
Ratchet wrench
Fluid container
Funnel
Fender cover
Buy tools
Replacement: engine thermostat – VW PASSAT Variant (3B5). Tip from AUTODOC:
  • Check the condition of the coolant every time you replace the thermostat. Change the coolant if necessary.
  • Please note: all work on the car – VW PASSAT Variant (3B5) – should be done with the engine switched off.
Carry out replacement in the following order:
  1. Step 1
    Open the hood.
    Step 2
    Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
    Step 3
    How to change Thermostat on Passat 3b5 1997 - free PDF and video manuals
    Unscrew the coolant reservoir cap.
  2. Step 4
    How to replace VW PASSAT Variant (3B5) 1.9 TDI 1998 Thermostat - step-by-step manuals and video guides
    Prepare a container for fluids.
  3. Step 5
    Passat 3b5 1.8 T 1999 Thermostat replacement: free workshop manuals
    Loosen the coolant hose clamp. Use a drive socket #7. Use a ratchet wrench.
  4. Step 6
    Changing Thermostat on VW PASSAT Variant (3B5) 1.6 2000 by yourself
    Detach the coolant hose.
  5. Step 7
    How to remove VW PASSAT 1.9 TDI Syncro/4motion 2001 Thermostat - online easy-to-follow instructions
    Drain the coolant from the engine.
    Replacement: engine thermostat – VW PASSAT Variant (3B5). Tip:
    Caution! The coolant can be very hot.Wear gloves to prevent contact with hot liquid.All work should be done with the engine stopped.Wait until the coolant has completely flowed out of the drain hole.
  6. Step 8
    How to replace Thermostat on VW PASSAT Variant (3B5) 1997: download PDF manuals and video instructions
    Unscrew the thermostat housing fasteners. Use a drive socket #13. Use a ratchet wrench.
  7. Step 9
    How hard is it to do yourself: Thermostat replacement on Passat 3b5 1.9 TDI 4motion 1998 - download illustrated guide
    Remove the thermostat housing.
    AUTODOC recommends:
    Replacement: engine thermostat – VW PASSAT Variant (3B5). Do not use excessive force when removing the part as this may damage it.
  8. Step 10
    Need to know how to renew Thermostat on VW PASSAT 1999? This free workshop manual will help you to do it yourself
    Remove the thermostat.
    AUTODOC recommends:
    Replacement: engine thermostat – VW PASSAT Variant (3B5). Do not use excessive force when removing the part as this may damage it.Caution! Coolant may leak out of the coolant lines and thermostat housing.
  9. Step 11
    Changing of Thermostat on Passat 3b5 2000 won't be an issue if you follow this illustrated step-by-step guide
    Install a new thermostat.
    Replacement: engine thermostat – VW PASSAT Variant (3B5). Tip:
    When installing, do not use excessive force to avoid damage to the part.
  10. Step 12
    VW PASSAT 1.9 TDI Thermostat replacement: online guides and video tutorials
    Install the thermostat housing.
  11. Step 13
    Replacing Thermostat on Passat 3b5 1997 1.9 TDI by yourself
    Tighten the thermostat housing fasteners. Use a drive socket #10. Use a torque wrench. Tighten it to 13 nm torque.
  12. Step 14
    PASSAT Variant (3B5) 1.9 TDI Syncro/4motion 1998 Thermostat DIY replacement workshop manual
    Attach the coolant hose.
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