How to carry out replacement: Thermostat 250 GD 2.5 Mercedes W461
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Change Mercedes W461 250 GD 2.5 Thermostat yourself – manuals and video tutorials

How to change temperature sensor and engine thermostat on MERCEDES-BENZ G-Class Off-Road (W461) – replacement guide

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When to replace the Thermostat on your MERCEDES-BENZ G-CLASS
Recommended replacement interval for the part category Thermostat : 50000 km
Important!
This replacement procedure can be used for:
MERCEDES-BENZ G-Class Off-Road (W461) 250 GD (461), MERCEDES-BENZ G-Class Off-Road (W461) G 290 TD (461.335, 461.336), MERCEDES-BENZ G-Class Off-Road (W461) 290 GD/G 290 D (461.337, 461.338) … 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 G-Class Off-Road (W461) and other MERCEDES-BENZ models
Alternative products
How to change Thermostat on Mercedes W461 250 GD 2.5 – step-by-step instructions for straightforward car repair Thermostat
Tools
Replacement: temperature sensor and engine thermostat – MERCEDES-BENZ G-CLASS (W461). Tools you'll need:
Wire brush
All-purpose cleaning spray
Dielectric grease
Torque wrench
Combination spanner #10
Combination spanner #19
Drive socket # 7
Drive socket # 10
Drive socket # 22
Ratchet wrench
Flat screwdriver
Funnel
Fluid container
Fender cover
Buy tools
Replacement: temperature sensor and engine thermostat – MERCEDES-BENZ G-CLASS (W461). AUTODOC experts recommend:
  • Check the condition of the coolant every time you replace the thermostat. Change the coolant if necessary.
  • All work should be done with the engine stopped.
  • All work should be done with the engine stopped.
Replacement: temperature sensor and engine thermostat – MERCEDES-BENZ G-CLASS (W461). Take the following steps:
  1. Step 1
    Open the bonnet.
    Step 2
    Use a fender protection cover to prevent damaging paintwork and plastic parts of the car.
    Step 3
    How to change Thermostat on Mercedes W461 1989 - free PDF and video manuals
    Loosen the air filter hose clamps. Use a drive socket #7. Use a ratchet wrench.
  2. Step 4
    How to replace MERCEDES-BENZ G-Class Off-Road (W461) 250 GD 2.5 1990 Thermostat - step-by-step manuals and video guides
    Remove the air intake hose.
  3. Step 5
    Mercedes W461 290 GD/G 290 D 2.9 (461.337, 461.338) 1991 Thermostat replacement: free workshop manuals
    Cover the throttle body with a microfibre towel to prevent dust and dirt from getting into the system.
  4. Step 6
    Changing Thermostat on MERCEDES-BENZ G-Class Off-Road (W461) 230 GE 2.3 1992 by yourself
    Unscrew the coolant reservoir cap.
  5. Step 7
    Lift the car using a jack or place it over an inspection pit.
    Step 8
    How to remove MERCEDES-BENZ G-CLASS 230 G 2.3 (461.238, 461.239) 1993 Thermostat - online easy-to-follow instructions
    Prepare a container for fluids.
  6. Step 9
    How to replace Thermostat on MERCEDES-BENZ G-Class Off-Road (W461) 1994: download PDF manuals and video instructions
    Open the coolant drain tap. Use a flat screwdriver.
  7. Step 10
    How hard is it to do yourself: Thermostat replacement on Mercedes W461 G 280 CDI (461.304, 461.334, 461.339, 461.344, 461.390) 1995 - download illustrated guide
    Drain the coolant from the engine.
    Replacement: temperature sensor and engine thermostat – MERCEDES-BENZ G-CLASS (W461). Tip:
    All work should be done with the engine stopped.Wait until the coolant has completely flowed out of the drain hole.
  8. Step 11
    Need to know how to renew Thermostat on MERCEDES-BENZ G-CLASS 1996? This free workshop manual will help you to do it yourself
    Unscrew the coolant drain plug on the engine block. Use a combination spanner #19.
  9. Step 12
    Changing of Thermostat on Mercedes W461 1997 won't be an issue if you follow this illustrated step-by-step guide
    Drain the coolant from the engine.
    AUTODOC recommends:
    All work should be done with the engine stopped.Wait until the coolant has completely flowed out of the drain hole.
  10. Step 13
    MERCEDES-BENZ G-CLASS 250 GD 2.5 Thermostat replacement: online guides and video tutorials
    Screw in the coolant drain plug on the engine block. Use a combination spanner #19.
  11. Step 14
    Replacing Thermostat on Mercedes W461 1999 250 GD 2.5 by yourself
    Close the coolant drain tap. Use a flat screwdriver.
  12. Step 15
    G-Class Off-Road (W461) 230 G 2.3 (461.238, 461.239) 2000 Thermostat DIY replacement workshop manual
    Clean the thermostat housing fasteners. Use a wire brush. Use all-purpose cleaning spray.
  13. Step 16
    How to change Thermostat on MERCEDES-BENZ G-Class Off-Road (W461) 2001 - tips and tricks
    Unscrew the thermostat housing fasteners. Use a combination spanner #10. Use a drive socket #10. Use a ratchet wrench.
  14. Step 17
    Step-by-step recommendations for DIY replacement Mercedes W461 2002 230 G 2.3 (461.238, 461.239) Thermostat
    Remove the fastening bolts.
  15. Step 18
    DIY replacement of Thermostat on MERCEDES-BENZ G-Class Off-Road (W461) G 290 2.9 Turbo Diesel (461.335, 461.336) 2003 is not an issue anymore with our step-by-step tutorial
    Loosen the coolant hose clamp. Use a drive socket #7. Use a ratchet wrench.
  16. Step 19
    How to change Thermostat on Mercedes W461 1989 - free PDF and video manuals
    Detach the coolant hose.
    Replacement: temperature sensor and engine thermostat – MERCEDES-BENZ G-CLASS (W461). AUTODOC recommends:
    Be careful! The coolant may leak.
  17. Step 20
    How to replace MERCEDES-BENZ G-Class Off-Road (W461) 250 GD 2.5 1990 Thermostat - step-by-step manuals and video guides
    Remove the thermostat together with the housing.
  18. Step 21
    Mercedes W461 290 GD/G 290 D 2.9 (461.337, 461.338) 1991 Thermostat replacement: free workshop manuals
    Clean the thermostat housing mounting seat. Use a wire brush. Use all-purpose cleaning spray.
  19. Step 22
    Changing Thermostat on MERCEDES-BENZ G-Class Off-Road (W461) 230 GE 2.3 1992 by yourself
    Remove the thermostat.
  20. Step 23
    Clean the thermostat mounting seat. Use a wire brush. Use all-purpose cleaning spray.
    Step 24
    How to remove MERCEDES-BENZ G-CLASS 230 G 2.3 (461.238, 461.239) 1993 Thermostat - online easy-to-follow instructions
    Install a new thermostat.
  21. Step 25
    How to replace Thermostat on MERCEDES-BENZ G-Class Off-Road (W461) 1994: download PDF manuals and video instructions
    Install the thermostat together with the housing.
  22. Step 26
    How hard is it to do yourself: Thermostat replacement on Mercedes W461 G 280 CDI (461.304, 461.334, 461.339, 461.344, 461.390) 1995 - download illustrated guide
    Install the fastening bolts.
  23. Step 27
    Need to know how to renew Thermostat on MERCEDES-BENZ G-CLASS 1996? This free workshop manual will help you to do it yourself
    Tighten the thermostat housing fasteners. Use a drive socket #10. Use a torque wrench. Tighten it to 12 Nm torque.
  24. Step 28
    Changing of Thermostat on Mercedes W461 1997 won't be an issue if you follow this illustrated step-by-step guide
    Attach the coolant hose.
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