How to remove alero trans coolant assembly seals

just did one today on my shop truck so its fresh in mind , 1st block under wheels so vehicle cant roll over you , then carefully drain the coolant (it might be hot!!) from drain plug next to bottom outlet to radiator hose into a large pan (save it ) locate top hose connection and remove it (one end only) then when coolant stops flowing out , remove one end of bottom hose , if equipped remove the auto trans cooler lines in middle of radiator too , cap them off to save fluid !! when its all unhooked remove holddown bolts from radiator (4) and remove it from vehicle some addl unhooking of fan shroud might be needed to do this , locate fan clutch (if equipped ) and using a band wrench , unscrew it , (left hand thread) that means turn it left to right remove fan and clutch/ drive belt pulley as an assembly , locate /remove water pump holddown bolts , there should be several of them (truck had 10) note the lengths of each bolt (different) as you;ll need to reinstall them exactly as you take em out when all out using a rubber mallet give the pump shaft a sharp blow, this will break the seal of gasket and if got all the bolts out pump will come off engines front ,remove it , clean all the old gasket from the engine face (don't get gasket pieces in coolant passages) install new gasket onto new pump and reinstall to engine , use new same length bolts if old ones look too nasty !! use same thread/ length bolts or you could damage engine block!!! torque the bolts to 19 to 25 inch pounds !! reinstall fan and clutch right to left this time , give the fan one tap with rubber mallet to seat it after contact , reinstall radiator and reconnect hoses (trans too), skim off any non coolant looking stuff from you pan with paper towels an refill the radiator with it , top off with fresh coolant to level , start engine and allow it to come to normal temp (20 minutes) look for any leaks or forgotten bolt holes , this is a simplified version of how to change a rear wheel drive or 4 wheel drive car/lite truck water pump , your exact details maybe different than these

2.3L Engine

Specific to:
Ford Fusion 2008-2009
Mercury Milan 2008-2009

1. Raise and safely support the vehicle.
2. Drain the cooling system.
3. Loosen the 3 coolant pump pulley bolts.
4. Remove the accessory drive belt.
5. Remove the 3 bolts and the coolant pump pulley.
   1. To install, tighten to 15 ft. lbs. (20 Nm).
6. Remove the 3 bolts and the coolant pump.
7. Remove and discard the O-ring seal.
   1. To install, tighten to 89 inch lbs. (10 Nm).
   
   

Fig. Exploded view of the water pump-2.3L engine


To install:

1. To install, reverse the removal procedure.
2. Lubricate the O-ring seal with clean engine coolant.
3. Fill and bleed the cooling system

3.0L Engine

Specific to:
Ford Fusion 2008-2009
Mercury Milan 2008-2009

1. Raise and safely support the vehicle.
2. Drain the cooling system.
3. Remove the coolant pump belt.
4. Using Special tool 303-S455, or equivalent, remove the coolant pump drive pulley.

Fig. Using Special tool 303-S455, or equivalent, remove the coolant pump drive pulley

5, Disconnect the heater hose from the coolant pump.
6. Disconnect the coolant pump-to-engine hose and position aside.
7. Remove the 3 bolts from the coolant pump assembly.
8. Reposition the coolant pump-to-thermostat housing hose clamp and remove the coolant pump and hose as an assembly.



Fig. View of the water pump and related components-3.0L engine

To install:

1. Connect the coolant pump-to-thermostat housing hose and reposition the clamp.
2. Position the coolant pump assembly and install the 3 bolts:
   1. Tighten to 89 inch lbs. (10 Nm).
   2. Tighten the 3 bolts an additional 90 degrees.
3. Connect the coolant pump-to-engine hose and the heater hose.
   NOTE
   Install the coolant pump drive pulley flush with the end of the camshaft.
4. Using Special tools 211-185 and 303-S455, or equivalent, install the coolant pump drive pulley.

Fig. Using Special tools 211-185 and 303-S455, or equivalent, install the coolant pump drive pulley

5. Install the coolant pump belt.
6. Fill and bleed the cooling system.

REPLACE WATER PUMP ON A 1999 OLDSMOBILE ALERO. FIRST YOU HAVE TO DRAIN COOLANT SYSTEM IN A LARGE DRAIN. RADIATOR DRAIN PLUG SHOULD BE ON THE BOTTOM ON PASSENGER SIDE. THEN RAISE THE VECHICLE SUPPORT VECHICLE WITH JACKSTANDS. REMOVE THE EXHAUST MANIFOLD FROM THE ENGINE. CAUTION DO NOT ROTATE THE FLEX COUPLING ON THE FRONT EXHAUST PIPE MORE THAN 4 DEGREE OR DAMAGE TO THE FLEX COUPLING MAY OCCUR. REMOVE THE THERMOSTAT AND THE COOLANT INLET PIPE FROM THE WATER PUMP HOUSING AND SEPARATE THE ASSEMBLY FROM THE ENGINE. LOWER THE VECHICLE REMOVE THE BRAKE BOOSTER VACUUM HOSE FROM THE CAMSHAFT HOUSING. REMOVE THE FRONT TIMING CHAIN COVER AND THE TIMING CHAIN TENSIONER FROM THE ENGINE. CAUTION THE TIMING CHAIN TENSIONER MUST BE REMOVED TO UNLOAD CHAIN TENSION BEFORE REMOVING THE WATER PUMP FROM THE HOUSING OTHERWISE THE WATER PUMP WILL BECOME JAMMED IN THE TIMING CHAIN HOUSING. REMOVE THE HEATER OUTLET PIPE FROM THE WATER PUMP COVER. REMOVE THE WATER PUMP COVER BOLTS FROM THE ENGINE BLOCK AND THE WATER PUMP. REMOVE WATER PUMP RETAINING NUTS AND SEPARATE THE WATER PUMP FROM THE TIMING CHAIN HOUSING. CLEAN THE SEALING SURFACES OF ALL GASKET MATERIAL ON THE WATER PUMP, WATER PUMP COVER AND THE TIMING CHAIN HOUSING. WIPE THE MATING SURFACES WITH A RAG SATURATED LACQUER THINNER OR ACETONE. YOU CAN BUY THESE CHEMICAL AT LOWES OR WALMART DEPARTMENT WHERE THEY SELL PAINTS. FIRST INSTALL THE WATER PUMP COVER AND GASKET TO THE WATER PUMP ON THE BENCH BUT LEAVE THE BOLTS FINGER TIGHT. APPLY A THIN LAYER OF RTV SEALANT TO BOTH SIDES OF THE NEW GASKET AND INSTALL THE GASKET ON THE WATER PUMP. WAIT FOR RTV SEALANT SET UP DRY FIRST. POSITION WATER PUMP AND WATER PUMP COVER ASSEMBLY INTO TIMING CHAIN HOUSING ENGAGING THE WATER PUMP SPROCKET IN THE TIMING CHAIN, AND INSTALL THE NUTS FINGER TIGHT. USE CAUTION TO ENSURE THAT THE GASKET DOESNT SLIP OUT OF POSITION. LEAVE THE NUTS LOOSE TO ALLOW REPOSITIONING WHEN THE BLOCK BOLTS ARE INSTALLED IN THE NEXT STEP. INSTALL THE WATER PUMP COVER TO ENGINE BLOCK BOLTS AND TIGHTEN THEM BY HAND. LUBRICATE THE O - RING ON THE HEATER OUTLET PIPE WITH COOLANT AND INSTALL IT INTO THE WATER PUMP COVER. HAND TIGHTEN THE BOLTS. NOW THAT THE ENTIRE WATER PUMP HOUSING ASSEMBLY IS INSTALLED AND IS FITTED AGAINST THE ENGINE BLOCK. TIGHTEN BOLTS CRISS CROSS SEQUENCE TO INSURE PROPER SEAL TORQUE WATER PUMP TO TIMING CHAIN HOUSING NUTS TO 19 FT LBS .NOW TORQUE WATER PUMP COVER TO WATER PUMP HOUSING BOLTS TO 124 INCH POUNDS. TORQUE WATER PUMP COVER TO ENGINE BLOCK BOLTS 19 FT LBS. TORQUE 124 INCH POUNDS THE RADIATOR OUTLET PIPE TO WATER PUMP HOUSING. INSTALL THE TIMING CHAIN TENSIONER AND COVER. INSTALL THE EXHAUST MANIFOLD. INSTALL THE EXHAUST PIPE TO THE EXHAUST MANIFOLD. WHEN ALL IS DONE. START POURING COOLANT IN THE RADIATOR OR COOLANT OVER FLOW JUG.CHECK FOR LEAKS. IF IS GOOD KEEP ADDING COOLANT TO RADIATOR OR OVER FLOW RESERVOIR UNTIL COOLANT LEVEL STOP DROPPING. NOW START ENGINE. WATCH THE COOLANT LEVEL WHEN START DROPPING ADD MORE COOLANT IN RADIATOR OR OVERFLOW JUG. WHEN COOLANT STOP DROPPING INSTALL RADIATOR CAP OR OVERFLOW JUG CAP. LET ENGINE IDLE UNTIL THERMOSTAT OPENS WATCH TEMPERATURE GAUGE WHEN TEMPERATURE GAUGE RISING TO OVERHEATING. TURN OFF ENGINE WAIT A WHILE TAKE A LARGE RAG SLOWLY OPEN RADIATOR CAP A LITTLE TO RELEASE PRESSURE. WHEN PRESSURE RELEASE REMOVE RADIATOR CAP ADD MORE COOLANT. START ENGINE LET IDLE WATCH TEMP GAUGE. TEMP GAUGE START RISING AGAIN TURN OFF ENGINE LET IT SET A WHILE ADD MORE COOLANT. TO RADIATOR. WHEN ENGINE TEMPERATURE GAUGE STOP RISING AND THERMOSTAT OPENS YOUR COOLANT SYSTEM AIR IS BLED OUT. JUST LET VECHICLE SET A LITTLE CHECK COOLANT LEVEL MAKE ITS CORRECT BEFORE START DRIVING VECHICLE. IF YOU TAKE VECHICLE FOR TEST SPIN TAKE LARGE RAG AND PLENTY COOLANT WITH YOU.IF ENGINE START OVERHEATING WHILE DRIVING PULL OFF ROAD SAFELY WAIT 20 TO 30 MINUTES. USE LARGE RAG SLOWLY OPEN CAP A LITTLE RELEASE PRESSURE. THEN REMOVE RADIATOR CAP ADD MORE COOLANT IF NEEDED. HOPE THIS HELP.

REMOVAL

1. Remove upper intake manifold.
2. Partially drain cooling system below the thermostat level.
3. Remove upper radiator hose from outlet connector.
4. Remove coolant recovery system hose from outlet connector.
5. Remove coolant outlet connector bolts.
6. Remove thermostat assembly, and clean sealing surfaces.

INSTALLATION

1. Place the new thermostat assembly into the coolant outlet connector, aligning air bleed with the location notch on outlet connector.
2. Install coolant outlet connector with thermostat in position onto thermostat housing. Tighten bolts to 12.5 Nm (110 inch lbs.).
3. Install upper radiator hose.
4. Connect the coolant recovery system hose.
5. Install upper intake manifold.
6. Fill cooling system.
7. see thermostat mounting are below

Thermostat Removal & Installation 2.2L Engine To Remove:

1. Remove the exhaust manifold. If equipped with an automatic transmission.
2. Drain the cooling system.
3. Remove or disconnect the following:
   
   
   • Thermostat housing to water pump feed pipe bolts.
     
     
   • Thermostat housing to water pump feed pipe.
   • Thermostat.

To Install:

1. Install or connect the following:
   • Thermostat.
   • Thermostat housing to water pump feed pipe.
   • Thermostat housing to water pump feed pipe bolt.
     1. Tighten bolt to 89 in lbs (10 Nm).
   • Exhaust manifold if equipped with an automatic transmission.
2. Fill the cooling system.

2.4L Engine To Remove:
Thermostat assembly 2.4L

1. Drain the cooling system.
2. Remove the exhaust manifold heat shield.
3. Remove the coolant inlet housing mounting bolts through the exhaust manifold.
4. Raise and safely support the vehicle.
5. Remove the coolant inlet housing stud from the oil pan.
6. Remove wheel and tire assembly.
7. Remove the engine splash shield.
8. Remove the mounting bolts from the transaxle-to-engine block support. Remove the support.
9. Remove the coolant housing pipe.
10. Remove the thermostat.
11. Clean the mating surfaces.

To Install:

1. Install the thermostat.
2. Install the coolant housing pipe.
3. Install and secure the transaxle support-to-engine block mounting bolts.
4. Install the engine splash shield.
5. Install the wheel and tire assembly.
6. Install the coolant inlet housing stud to the oil pan.
   • Tighten to 19 ft lb (26 Nm).
7. Lower the vehicle.
8. Install the coolant inlet housing bolts through the exhaust manifold.
   • Tighten the coolant inlet housing bolts to 10 ft lb (14 Nm).
9. Install the exhaust manifold heat shield.
10. Fill the cooling system.
11. Inspect the system for leaks.

3.4L Engine To Remove:

1. Drain the cooling system.
2. Remove the air cleaner.
3. Remove exhaust crossover pipe.
4. Disconnect the surge tank line fitting from the coolant outlet.
5. Remove the thermostat housing to intake manifold bolts.
6. Remove the thermostat housing outlet and thermostat.

To Install:

1. Install the thermostat and housing outlet.
2. Install the thermostat housing bolts.
   • Tighten the thermostat housing bolts to 18 ft lb (25 Nm).
3. Install exhaust crossover pipe.
4. Connect the surge tank line fitting to the coolant outlet.
   • Tighten the fittings to 15 ft lb (21 Nm).
5. Install the air cleaner.
6. Fill the cooling system.
7. Inspect the system for leaks

Hello, the thermostat on the Mazda Millenia is the heart of the coolant system. The thermostat regulates the flow of coolant to your motor and ensures your Mazda runs cool at all times. The thermostat acts as a valve to allow just enough coolant to flow through the system to maintain the engine temperature. When the engine temperature cools, the thermostat will close and pressurize the coolant. This cycle is what keeps your engine running cool.


To remove the thermostats follow this steps:
1. Pull the hood release latch under the steering wheel. Access the engine compartment to replace the thermostat.

2. Remove the top radiator hose by unscrewing the hose clamps with a flat-head screwdriver. The hose clamp may have a hose clamp requiring pliers. This clamp will have two tabs on it. Pull the tabs together to loosen the hose clamp.

3. Remove the bolts at the top of the thermostat assembly. The radiator hose will stop at the thermostat assembly.

4. Remove the top portion of the thermostat assembly. The thermostat will be sitting in the bottom portion.

5. Remove the thermostat with your fingers. The thermostat is positioned a particular way. Remember the position it was sitting in the housing.

And for installing the thermostats follow the following steps:

1. Place the new thermostat in the housing. Remember the position of the old one.

2. Lay down the gasket around the surface of the housing. Scrape off the old gasket with a putty knife or a razor blade.
3. Tighten the housing back together. You will want the housing snug to help create a seal for the assembly.

4. Install the radiator hose back on the assembly and the radiator. Tighten the hose clamp snug.

5. Refill the coolant level back to full. Some coolant may have been lost during the replacement.


Thanks

2.0L & 2.4L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
   CAUTION This operation must only be performed on a cold engine.
3. Drain cooling system to the thermostat level or below.
4. Remove or disconnect the following:
   Coolant recovery system hose Thermostat/engine outlet connector bolts Inlet hose and coolant elbow from thermostat housing
5. Remove thermostat assembly and clean sealing surfaces.
   
   
   Fig. Thermostat and housing-2.0L and 2.4L engines
   

To install:

1. Place the new thermostat assembly into the engine outlet connector. Align air bleed with notch on the cylinder head.
2. Install engine outlet connector onto cylinder head and tighten bolts to 110 inch lbs. (12.5 Nm)
3. Connect the coolant recovery system hose.
4. Fill cooling system.

1. Drain cooling system to the thermostat level or below.
2. Remove the Coolant Recovery System (CRS) hose and thermostat/engine outlet connector bolts.
3. Remove the thermostat assembly, and clean sealing surfaces.
   
   
   Fig. Thermostat assembly-2.0L engine
   
   
   
   Fig. Thermostat assembly-2.4L engine
   

To install:

1. Place the new thermostat assembly into the engine outlet connector.
   1. Align air vent upward with notch on the cylinder head (2.0L engine).
   2. Make sure spring side of thermostat faces cylinder head.
      
   
   
2. Install the engine outlet connector onto cylinder head and tighten bolts to 110 inch lbs. (12.5 Nm)
3. Connect the Coolant Recovery System (CRS) hose.
4. Fill cooling system.

2.4L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system to the thermostat level or below.
3. Remove the Coolant Recovery System (CRS) hose and thermostat/engine outlet connector bolts.
4. Remove the thermostat assembly, and clean sealing surfaces.
   
   
   Fig. Thermostat assembly-2.4L engine
   

To install:

1. Place the new thermostat assembly into the engine outlet connector.
2. Make sure the spring side of the thermostat faces the cylinder head.
3. Install the engine outlet connector onto cylinder head and tighten bolts to 110 inch lbs. (12.5 Nm)
4. Connect the CRS hose.
5. Fill the cooling system to the proper level.

Hope help with this (remember rated this post).

You're going to lose some coolant, so have a bucket or other container, and some fresh coolant ready. Follow the upper radiator hose to the point where it's connected to the engine. The hose is clamped to a metal housing (water inlet) which is bolted to the engine. Remove the bolts (not the hose) and lift the housing to expose the thermostat (may require a little prying with a screwdriver or similar tool). Note how the old thermostat is fitted (which end is up), lift it out of the engine, and then remove all traces of gasket from the housing and the engine. Install the new thermostat and gasket, replace the bolts, add coolant as necessary, and you're done.

YOU HAVE TO REMOVE EXHAUST MANIFOLD HEAT SHIELD THEN REMOVE COOLANT INLET PIPE FROM THE THERMOSTAT HOUSING BY ACCESSING BOLTS THROUGH THE EXHAUST MANIFOLD RUNNERS.RAISE THE VECHICLE SECURE IT ON JACK STANDS REMOVE THE ENGINE TO TRANSAXLE SUPPORT BRACE.REMOVE THE LOWER RADIATOR HOSE FROM THE COOLANT PIPE.REMOVE THE COOLANT INLET PIPE TO OIL PAN STUD AND CAREFULLY SEPERATE COOLANT INLET PIPE FROM THERMOSTAT HOUSING.SLIDE THE COOLANT PIPE PAST THE RIGHT OF THE TRANSAXLE TO REMOVE IT.NOTE HOW ITS INSTALLED THEN REMOVE THE THERMOSTAT FROM THE INLET PIPE.

try getting the freeze plugs checked out. =]