GATES THERMOSTAT 1489

Great mod, we have been doing these since 2008 on the R40, I have a few to do at our R40 meet on the 15th & 16th Oct, my order arrived yesterday just in time, as I had ran out, we will also be checking out FBH as some times the PCB board can go wrong, and need repairing, by our resident French Mike keep warm this winter guys

My stat arrived today. Strangely, it came from France, hence the delay.

I am assuming I will need to remove the engine cover to get better access to the band that needs cutting?

dog-man said:

My stat arrived today. Strangely, it came from France, hence the delay.

I am assuming I will need to remove the engine cover to get better access to the band that needs cutting?

Click to expand...

I had to take off the inlet manifold as I couldn't get the connector to shift. I used an angle grinder to cut the band without removing it but made sure there was an old coat over the engine to stop any bits getting into it.

Alibro said:

I had to take off the inlet manifold as I couldn't get the connector to shift. I used an angle grinder to cut the band without removing it but made sure there was an old coat over the engine to stop any bits getting into it.

Click to expand...

When you say 'connector', I assume you are not referring to the steel band. What connector?

The one on the end of the pipe. It should pull off but I struggled for a few minutes then gave up and cut the band with it still connected as you can see here.

dog-man said:

When you say 'connector', I assume you are not referring to the steel band. What connector?

Click to expand...

Steer clear of trying to remove the connector from the Y junction as it can and doe's fracture as the plastic gets brittle over time, remove the manifold and use a triangle file cut the band off, then remove the hose form the car it will be easier to insert the thermostat in to the hose.

I don't have the Y junction on my manual TD4.


*****Correction******

I do have that exact Y junction. I couldn't see it until I removed the manifold.

By how much should the stat be sticking out beyond the rim of the hose if at all?

I have the stat in the hose now but not sure if it's in far enough.

dog-man said:

By how much should the stat be sticking out beyond the rim of the hose if at all?

I have the stat in the hose now but not sure if it's in far enough.

Click to expand...

Hopefully I am not to late to answer your question I have only just got in, the end of the stat can be flush with the end of the hose or maybe 5-10 mm inside few pics below for you.

Mine needs to go further then.

How safe is it to really wack it with a pipe to get it in further.
I don't want to break the damn thing before it gets a chance to do it's job.

Your hose looks bigger than mine.


06 TD4 manual.

dog-man said:

Mine needs to go further then.

How safe is it to really wack it with a pipe to get it in further.
I don't want to break the damn thing before it gets a chance to do it's job.

Your hose looks bigger than mine.


06 TD4 manual.

Click to expand...

Use a piece of pipe to push it in so you don't damage it. With a manual it should go in quite easily with plenty of lubrication.

I am struggling to get it in as far as you seem to have managed.

I tried boiling water, a hot air gun and plenty of lubrication of various types.
It seems to fit to the pastic end piece as it is without the plunger part making contact with anything, so not sure if I am going to risk it or try again.

Cup of tea and a head scratch I think is in order.

I found using a 32mm socket helped it just fits inside the pipe still couldn't get mine in all the way though the tip stuck out about 5mm and it was stuck fast,tried the pipe back on the y shaped connector and it slid on back where it was so fixed back on and even with it stuck out 5mm it works fine and dandy temp gauge up to 12 0' clock with 3 miles nice and toasty now

Mine is sticking out 10 mm beyond the end of the hose.

I am going to try and source some plumbers grease and have one more try.
If after that I find that its still sticking out by 10 mm, I will leave it at that as it does fit back in the end piece without any issues.

I found with using a socket you can hold vertical with one hand and tap the socket with a hammer
I was in same boat as you refitted mine with 5mm sticking mine works fine good luck and
it makes a real difference

I have managed to source some plumbers grease locally and it wasn't easy.
Loads available online but locally, only ToolStation have some out of all the big name stores you would expect to find some.
So I will have another try using that.

I am now convinced that my hose is smaller than it should be.
I can only get a 30mm socket into the hose and not a 32mm socket.

Even with plumbers grease, I can only get the stat in with now around 8mm sticking out so that will have to do.
Beginning to get dark now so will re-assemble tomorrow and road test.

Have you tried Fairy Liquid like mudinuri's Mrs suggested?

First thing I tried.

Sounds like your hose is smaller than mine then cause mine slipped in nice and easy.