Is your coolant tank cap falling apart? It was on my old 2.0L, to where I could scratch the threads off with my thumb. A replacement from an autoparts store is less than $10. Worth a try.
So it's the thermostat seal that was pinched? Is the thermostat still good? I had a case on the 2.0L where it would stick closed intermittently, and cause the car to boil over (via expansion tank).
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Currently: 1995 Mercedes E320; 2004 Porsche 986 Boxster
Previously: Phahom, 2005 Beetle 1.8T; Milen, 2000 Beetle 2.0L; Daku, 2007 GTI 2.0T; Mateka, 2003 Beetle TDI
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