Mercedes-Benz Case Study · 120

Mercedes-Benz CLA200 thermostat module, replaced.

A Mercedes-Benz CLA200 came in losing coolant from a cracked plastic thermostat housing. The whole module was replaced, the system bled and pressure tested, no more loss.

Job done

Mechanical Repairs Cooling System Mercedes-Benz Specialist
Mercedes-Benz CLA200 parked at the workshop, in for a coolant leak diagnosis.

The brief

The CLA200 kept needing coolant topped up between services, the level dropping with no obvious puddle and a faint sweet smell. He brought it in, which is exactly right, coolant that disappears is going somewhere and a slow leak turns into an overheat the day it lets go. On this engine the thermostat lives inside a plastic housing module bolted to the engine, and that module is a known weak point: the plastic heat-cycles under pressure for years until it gets brittle and cracks, usually at a seam or a port, and it weeps coolant that the engine heat dries off so you barely see it. The thermostat inside can also stick with age. Either way, the housing isn't a part you patch, the whole module comes as one assembly with the thermostat in it, so a cracked housing means a new module.

The diagnosis

A pressure test on the cooling system pinpointed it, the plastic thermostat housing module was weeping from a hairline crack and bleeding pressure slowly, which is the disappearing coolant. The radiator, the hoses, the water pump and the rest of the system held fine. That's a module replacement, the thermostat and the housing are one unit, so the call was a complete thermostat module with a fresh seal.

Pressure test on the Mercedes-Benz CLA200 cooling system finding the leak.

The work

The cooling system was drained enough to get at it, the old cracked thermostat module removed, and a new genuine Mercedes-spec module fitted with a fresh seal and the connections renewed. The system was refilled with the correct Mercedes coolant, bled the proper way so no air pockets were left, and pressure tested again to confirm it held with no weep. A road test confirmed the gauge sat steady, the engine warmed up on time, and the level stayed put.

The old cracked plastic thermostat module removed from the engine.

The outcome

No more coolant loss, the level holding between checks, the gauge steady, the engine warming up on time, and the system holding pressure. The CLA200 went home with the leak resolved. A cracked thermostat housing only splits further, and the failure at the end is a sudden coolant dump and an overheat, so changing the module kept it to a tidy, planned job.

Got something similar?

Mercedes losing coolant?

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