Resolved 1G Turbo Thermostat Housing Confusement

[packrat]

Ok, So I just got this 94 tsi Thursday last week, and I took it for a run to see how she did, after this I would take care of the issues I noticed. 200 miles later, the thermostat got stuck open. (I take long rides). So I thought, no worries, simple job. 2 bolts no biggie. Wrong.
I got one of the bolts out no problem, the other snapped off in my hands, and I didn't even put much pressure on it. I tried using a reverse thread bit to back it out, and it broke. Tried torching the housing, that didn't work either. Vice grips? No dice. Tried drilling a smaller hole for a smaller bolt - couldn't get enough torque on the bolt I had, so now it's currently held together with a vice grip... I hope this gets me through till the new housing shows up....

As I have been reading around the forums, I have noticed that there is some weirdness concerning the thermostat housings. (This is for turbo motors only).
As I am aware, there are differences btwn the 1ga and 1gb motors, and the 2g motors.
So am I to understand that 1ga thermo housings have 4 bolts, and 1gb have 3 bolts, and so do the 2gs, but their water flanges are shaped differently?
Is there anyway we could put some pics of these (Unmodified) together so n00bs to DSMs like me could check this out?
I ordered one offa DSM Graveyard and after much googling and image comparing to the one in my car I felt like I could order it without freaking out I bought the wrong one - listed here:
DSM Graveyard - Your #1 Source for DSM Parts!

This thread http://www.dsmtuners.com/forums/new...using-coolant-line-connections-one-extra.html
shows the 1ga turbo thermostat housing, so that's one. I will take a picture of mine when it comes out of the car upon the arrival of my new lower housing. and a 2g could be added to this as well.

Thoughts?

 

[bryanwheat]

1g turbo cars all use the same housing. Non turbo cars use a slightly different one that doesn't have the supply ports for the turbo and oil cooler.

 

[19Eclipse90]

All 1G 4G63 thermostat housings are mounted by three bolts / studs; all 2G 4G63 housings are mounted by four bolts. I edited this picture in an effort to make the visualization of the different housing flanges easier for everyone to see. Maybe it will help.

 

[packrat]

Fantastic! This is perfect.
There were a lot of discrepencies througout the forum searches.
The noted thread however speaks of an extra coolant nipple on the front of the lower thermostat housing from 91-94 - is this true as well?
Thanks,
Packrat

 

[ed1380]

Yes that's water supply to the turbo. 95-99 has a banjo in the block that provides the water to the turbo.

 

[19Eclipse90]

The 1990 turbo model came with an external (air) oil cooler, not a water cooler like the 1991-1994 turbo models. This is what the extra nipple is for in those later models -- to feed the water-cooled oil cooler -- hence why the picture in the other thread only has one which feeds the turbo.