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Anonymous Posted on Feb 26, 2010

6.5 Diesel Thermostat Housing Bolt Access: Gentlemen, I have marveled at the idiocy of the alternator bracket housing, cursed long and loud over the near psychosis of the water pump mounting, and have detoured into the perplexing case of the gigantic Torx bolt on the belt tensioner. I am now faced with the lower bolts on the dual thermostat housing. How, pray tell, does one remove these hidden treasures. I am but a simple shade tree novice, raised on the silly old 2 bolt thermostat housing. What to I have to remove, disassemble or otherwise warp into hyperspace to achieve the monumentally simple task (yeah, right) of replacing the thermostats on this vehicle?

  • Anonymous Feb 26, 2010

    Thanks Ben, but no way. That does not appear to be possible. Again, the question is, what do I have to remove to do this job. I do NOT want to start tearing stuff off the motor on a hit or miss basis. Can I do this job by removing the Turbo cover? Or the turbo cover and other stuff?

  • Anonymous Feb 26, 2010

    I'll take it, but be aware that the bottom driver side bolt can only be accessed easily if you remove the A/C compressor. Otherwise, you need to come in with a flex socket from the rear. In my case, it cannot be done because the bolt has been in place for 250,000 miles. Breaker bar doesn't work on an angle with a flex socket, or at least let's say I am not going to destroy a flex socket in the attempt. no more GM products for me, EVER.

×

2 Answers

ZJ Limited

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  • GMC Master 17,989 Answers
  • Posted on Feb 26, 2010
ZJ Limited
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GM Full-Size Trucks 1988-1998 Repair Information
Thermostat - REMOVAL & INSTALLATION

Diesel Engines
1988-95 models

  1. Remove the upper fan shroud.
  2. Drain the cooling system to a point below the thermostat.
6.5 Diesel Thermostat Housing Bolt - 1644db1.jpg

Fig. 9: Thermostat housing-6.2L engines, R/V series

661442f.jpg

Fig. 10: Thermostat housing-6.2L and 6.5L diesel engines-1988-95 C/K series
  1. Remove the engine oil dipstick tube brace and the oil fill brace.
  2. Remove the upper radiator hose.
  3. Remove the water outlet.
  4. Remove the thermostat and gasket.
  5. Installation is the reverse of removal.
  6. Use a new gasket coated with sealer, Make sure that the spring end of the thermostat is in the engine. Tighten the bolts to 35 ft. lbs. (47 Nm) on 1988-91 models and 31 ft. lbs. (42 Nm) on 1992-95 models.

1996-98 Models

  1. Drain the cooling system to a point below the thermostat.
  2. Disconnect the upper radiator (inlet) hose from the thermostat outlet.
  3. Ufasten the thermostat housing bolt and stud, then remove the housing.
  4. Remove the gasket and the thermostat.
  5. Clean any remaining gasket from the thermostat hosing mating s6.5 Diesel Thermostat Housing Bolt - bdc4644.jpgpan>
bdc4644.jpg

Fig. 11: Exploded view of the thermostat assembly components-1996-98 diesel engines

To install:

  1. Place the thermostat into position in the housing, then install the gasket.
  2. Install the thermostat housing, the bolt and the stud. Tighten the bolt and stud to 31 ft. lbs. (42 Nm).
  3. Attach the upper radiator (inlet) hose to the thermostat outlet.
  4. Fill the cooling system.
  5. Start the engine with the radiator cap still removed, until the upper radiator hose is hot (this means the thermostat is open).
  6. With the engine idling, add coolant until the coolant level reaches the bottom of the filler neck.
  7. Instal the radiator cap making sure the arrows line up with the overflow tube and check for coolant leaks.
continue...

  • ZJ Limited
    ZJ Limited Feb 26, 2010

    f
    Thermostat Housing Crossover - REMOVAL & INSTALLATION
    (This is found on the 6.2 and 6.5L diesel engines only)




    CAUTION

    Never open, service or drain the radiator or cooling system when
    hot; serious burns can occur from the steam and hot coolant. Also, when
    draining engine coolant, keep in mind that cats and dogs are attracted
    to ethylene glycol antifreeze and could drink any that is left in an
    uncovered container or in puddles on the ground. This will prove fatal
    in sufficient quantities. Always drain coolant into a sealable
    container. Coolant should be reused unless it is contaminated or is
    several years old.







        Drain the cooling system.


        Remove the engine cover.


        Remove the air cleaner and CDR valve.




    Fig. 1: Thermostat housing crossover-1988-91 R/V series











    Fig. 2: Thermostat housing crossover-1988-96 C/K series










    Fig. 3: Thermostat housing crossover-1997-98 C/K series






        Remove the air cleaner resonator and bracket.


        Remove the upper fan shroud.


        Remove the upper alternator bracket.


        Remove the bypass hose.


        Remove the upper radiator hose.


        Disconnect the heater hose.


        Remove the attaching bolts and lift out the crossover.


    To install:



        Thoroughly clean the mating surfaces.


        Position the crossover, using new gaskets coated with sealer.


        Install the attaching bolts and tighten them to 35 ft. lbs. (47
        Nm) on 1988-91 engines, or 31 ft. lbs. (42 Nm) on 1992-98 engines.



        Connect the heater hose.


        Install the upper radiator hose.


        Install the bypass hose.


        Install the upper alternator bracket.


        Install the upper fan shroud.


        Install the air cleaner resonator and bracket.


        Install the air cleaner and the CDR valve.


        Install the engine cover.


        Fill the cooling system.

    Hope help with this.


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Anonymous

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  • Master 389 Answers
  • Posted on Feb 26, 2010
Anonymous
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Hello, my name is Ben. I understand your frustration with this 4 bolt housing. After you remove the upper radiator hose, take a long extension and work from the rear of the engine. It's difficult but it can be done. And of course be very careful with re-installing those bolts so as to not cross thread them. Clean the gasket surfaces real good, obviously you do not want to go through this again. I hope this helps, good luck.

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I don't have a diagram. Here are the steps.
1) disconnect negative battery wire..
2) remove serpentine belt
3) remove upper heater hose and thermostat housing; leave thermostat in place
4) remove plate from in front of the power steering pump, the lower bolt is one of three of the alternator bolts.
5) remove all 5 bolts from the PS pump bracket - 2 are by the thermostat housing. Remove the bracket.
6) move the PS pump off to the side out of your way.
7) Remove the long bolt from the alternator you can now see. There is one more alternator bolt at the top which will allow you to remove the idler pulley bracket with the serpentine tensioner. This idler bracket and the tensioner bracket are sizeable, so you have to understand the volume of stuff you are removing.
8) Unhook the alternator wire and with some patience, if you have any left, you can squeeze the alternator out.
This procedure assumes you have the ability to do the serpentine belt removal and refitting, and you will need 12mm sockets/wrenches to do the rest. The t-stat housing uses the torx head screws, so you need that as well.
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How do you remove the bottom bolt of the thermostat housing on a 2004 trailblazer v6

V-6? Unless you've done an engine swap, it's an I6. With the stock I6 engine, must remove alternator and alternator bracket. Using a ratcheting wrench will help a ton for both the bottom bolt for the alternator and the thermostat, because the A/C lines are in the way, hard to get a socket in there.
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Where do you find and change a thermostat on a 1988 F250 7.3 diesel?

a108892a.gif

Section 03-01D: Diesel Engine, 7.3L V-8 1992 Bronco/Econoline/F-Series Workshop Manual
REMOVAL AND INSTALLATION Please rate highly if this helps. this is 1992, only thing I have, should be the same. Thermostat A poppet-type thermostat is used with the engine. When the thermostat is closed, coolant flows to the water pump through a bypass passage at the front of the engine. When the thermostat is open, coolant flows through the coolant outlet elbow (thermostat housing) to the radiator. ani_caut.gif CAUTION: Replacement thermostats other than the specified Motorcraft or Navistar thermostats may result in engine overheat damage. The specified thermostat does not contain an internal bypass, since the by-pass is located in the cylinder block. Therefore, whenever the thermostat is replaced, it is mandatory that only Motorcraft E5TZ-8575-C or Navistar 1807945-C1 thermostat be installed.
The thermostat is a high temperature thermostat for use with a mixture of water and permanent-type antifreeze. ani_caut.gif CAUTION: Do not attempt to repair the thermostat. It should be replaced if it is not operating properly.
Check the thermostat before installing it, following the procedure described in this section.

Thermostat Design (Acceptable vs. Unacceptable)


a119101a.gif

Removal
  1. Disconnect ground cables from both batteries. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
  1. Drain coolant from radiator until coolant level is below thermostat. Refer to Section 03-03, Engine Cooling.
  1. Loosen and remove alternator and vacuum pump drive belts.
  1. Remove alternator. Position alternator out of the way.
  1. Remove vacuum pump and bracket. Position pump out of the way.
  1. Remove all but the lowest alternator/vacuum pump mounting casting bolt. Loosen the lowest bolt and pivot the alternator/vacuum pump casting outboard.
  1. Remove the water outlet housing attaching bolts. Bend the radiator upper hose upward and remove the thermostat and gasket.
  1. Inspect thermostat as outlined in this section.
Installation
  1. Clean the water outlet housing gasket surfaces. Coat a new outlet housing gasket with Perfect Seal Sealing Compound B5A-19554-A (ESR-M18P2-A) or equivalent. Position the water outlet housing gasket on intake manifold opening.
  1. Install thermostat in crankcase opening with the copper pellet or element toward engine and the thermostat flange positioned in the recess. If thermostat is improperly installed, it will cause a restricted flow of coolant.
  1. Position the water outlet housing against the crankcase. Install and tighten the attaching bolts to specification listed at the end of this section.
  1. Reposition the alternator/vacuum pump casting. Install attaching bolts.
  1. Install vacuum pump with bracket and tighten to specification. Refer to Section 03-05, Accessory Drive.
  1. Install alternator and drive belt.
  1. Install vacuum pump drive belt.
  1. Adjust alternator and vacuum pump drive belts to specification. Refer to Section 03-05, Accessory Drive.
  1. Fill and bleed the cooling system. Refer to Section 03-03, Engine Cooling.
  1. Connect ground cables to both batteries.
  1. Operate the engine until normal operating temperature is reached, then check the coolant level. Inspect cooling system for leaks. ani_caut.gif WARNING: DO NOT STAND IN LINE WITH OR NEAR RADIATOR FAN WHEN REVVING ENGINE.
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I need a diagram to replace the thermostat

I seriously doubt if you will find the diagram that you are asking for. The thermostat is very easy on most vehicles. Simply follow the upper radiator hose to where it connects to the engine. This would be the thermostat housing. The thermostat hosing is held on by 2 bolts. Remove the 2 bolts and remove the thermostat housing. The thermostat will be under the housing. Pull the old thermostst out and clean the gasket surfaces on both the engine and the thermostat housing. install the new thermostat and thermostat housing gasket and reinstall ithe thermostat and bolts. On some of the Dodge vehicles it is necessary to remove the alternator and/or power steering pump/ A/C compressor brackets to access the thermostat housing bolts.
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Where Is thermostat located on 1994 escort 1.9 motor

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Need location of thermostate

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  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2. Remove or disconnect the following:
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    • Support bracket located near rear of alternator (A/C Vehicles) dod_trk_releasebelttension.gif

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To Install:
  1. Clean intake manifold and thermostat housing mating surfaces.
  2. Install or connect the following:
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    • Housing-to-intake manifold bolts.
      1. Torque to: 200 inch lbs. (23 Nm)
    • Upper radiator hose to thermostat housing dod_trk_drivebeltrouting.gif

    • Alternator (A/C Vehicles)
      1. Torque to: 30 ft. lbs. (41 Nm)
    • Support bracket
      1. Torque to: 40 ft. lbs. (54 Nm)
    • Drive belt over all pulleys except idler pulley
    • Socket/wrench to pulley mounting bolt of automatic tensioner and rotate clockwise
    • Belt over idler pulley, let tensioner rotate back into place and remove wrench
    • Coolant
    • Negative battery cable
  3. Start and warm the engine and check for leaks.
4.7L Engine To Remove:
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2. Remove or disconnect the following:
    • Negative battery cable
    • Coolant
  3. Safely raise and support the vehicle.
  4. Remove or disconnect the following:
    • Splash shield
    • Lower radiator hose clamp and lower radiator hose at thermostat housing 4.7L engine shown 3.7L similar chry_47_thermostst.gif

    • Thermostat housing mounting bolts, thermostat housing and thermostat
To Install:
  1. Clean timing chain cover and thermostat housing mating surfaces.
  2. Install or connect the following:
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    • Thermostat housing on timing chain cover
    • Housing-to-timing chain cover bolts.
      1. Torque to: 112 inch lbs. (13 Nm)
    • Lower radiator hose on thermostat housing
    • Splash shield
  3. Lower vehicle.
  4. Fill cooling system.
  5. Connect negative battery cable to battery.
  6. Start the engine and check for leaks.
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1helpful
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MY 2001 TAHOE FAILED THE SAFETY INSPECTION BECAUSE THE "IDLER" ARM HAS A "FAIR AMOUNT OF PLAY. IS THEIR ANYTHING I CAN DO SHORT OF REPLACING THE ENTIRE IDLER ARM?

yes the entire idler arm needs replacement to clear this problem.
there are many things to be checked
just click this link directly
http://www.2carpros.com/maintenance/car_safety_inspection.htm
you will need to remove the alternator to replace the idler arm pulley
Disconnect the negative, then the positive battery cables.
Remove the battery from the vehicle.
Remove the battery tray using the following procedure:
Remove the four battery tray bolts.
Remove the battery tray from the vehicle.
Remove the serpentine drive belt.
Remove the cooling fan assembly using the following procedure:
Remove the wishbone-shaped engine mount strut by removing the bolts and nuts at the engine mount bracket and on the upper radiator support.
Remove the strut from the vehicle.
Disconnect the cooling fan harness from the engine wiring harness.
Reposition the wiring harness at the upper radiator support.
Remove the cooling fan shroud bolts.
Remove the right side radiator bracket.
Remove the cooling fan shroud with the electric cooling fan motors and fans as an assembly.
Remove the thermostat housing and the radiator hose using the following procedure.
Partially drain the engine coolant.
Use hose clamp pliers to remove the radiator hose clamp to the water inlet housing and disconnect the radiator hose.
Use hose clamp pliers to remove the heater hose clamp to the water inlet housing and disconnect the heater hose from the water inlet housing.
Use hose clamp pliers to remove the surge tank inlet hose clamp from the water inlet housing and disconnect the surge tank hose from the water inlet housing.
Remove the water inlet housing bolts and remove the water inlet housing.
Remove the outboard generator bolt and loosen the inboard bolt.
Remove the idler pulley bolt and idler pulley.
Unplug the electrical connector from the alternator.
Pull back the protective boot from the alternator "BAT" terminal, remove the nut and disconnect the heavy "BAT" wire from the alternator terminal stud.
Remove the alternator from the vehicle.
To Install:
Position the alternator to the engine.
Plug in the electrical connectors and install the heavy "BAT" wire to the alternator terminal stud. Tighten the nut to 15 ft. lbs. (20 Nm). Press the protective boot back in place over the stud terminal and nut assembly.
Install the outboard alternator bolt into the alternator housing.
Install the inboard alternator bolt and then finger-tighten the outboard bolt.
Install the idler pulley and idler pulley bolt.
Tighten the bolts in the following torque sequence:
Tighten the idler pulley bolt to 37 ft lbs. (50 Nm).
Tighten the alternator bolts to 37 ft. lbs. (50 Nm).
Install the water inlet and thermostat housing and the radiator hose, observing the following:
Inspect and clean the mating surfaces on the thermostat cover and its mounting surface on the engine.
Use RTV Sealer GM #1052366 or equivalent on the mounting bolts since the threaded openings are open to the cooling system and the torque requirement is low.
Install the water inlet and thermostat housing and tighten the bolts to 80 inch lbs. (9 Nm).
Connect the surge tank inlet hose to the water inlet housing.
Connect the heater hose to the water inlet housing.
Connect the radiator hose to the water inlet housing.
Install the cooling fan assembly and tighten the radiator bracket bolts to 80 inch lbs. (9 Nm). Plug in the wiring harness at the upper radiator support. Plug in the cooling fan wiring harness to the engine wiring harness.
Install the engine mount strut bracket to the upper radiator support first, insert the through bolt. Attach the engine side of the strut to the engine mount strut bracket on the engine and install the through bolt. Thread the nuts on the through bolts and tighten to 35 ft. lbs. (48 Nm).
Install the battery tray and tighten the bolts to 44 inch lbs. (5 Nm).
Install the battery.
Install the serpentine drive belt.
Connect the positive, then the negative battery cables.

This will help. Thanks please keep updated. please do rate the solution positively .thank you for using fixya.
12helpful
1answer

How to change a thermastat 1994 ford escort with a 1.9 engine

1.9L Engine

CAUTION Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.
  1. Disconnect the negative battery cable.
  2. Drain the cooling system.
  3. Remove the air intake tube, crankcase breather and PCV hose.
  4. Remove the ignition coil pack and bracket.
  5. Remove the upper radiator hose.
  6. Remove the ignition coil pack bracket.
  7. Unfasten the heater hose inlet tube bracket bolt and remove the heater hose inlet tube from the thermostat housing.
  8. Remove the three thermostat housing attaching bolts, then remove the thermostat housing and gasket.
b2d5ac4.jpg

Fig: Remove the ignition coil pack


b5ad3b2.jpg

Fig. : Detach the air intake tube, crankcase breather and PCV hose


3a3c4dd.jpg
Fig. : Disconnect the upper radiator hose from the radiator


63b3b74.jpg
Fig. : Unfasten the ignition coil pack bracket upper bolts...

076a94a.jpg

Fig. : ...and the lower bracket bolt, then remove the bracket

f656bf8.jpg

Fig. : Unfasten the heater hose inlet tube bracket bolt (arrow)

314321c.jpg

Fig: Unfasten the heater hose inlet tube-to-thermostat housing clamp


3204281.jpg
Fig.: Disconnect the hose inlet tube from the thermostat housing

5dc1ba9.jpg

Fig. : Unfasten the three thermostat housing bolts


2fb60e5.jpg

Fig. Separate the thermostat housing from the engine block


6f1527f.jpg

Fig. : Remove the thermostat from the housing


e33ea6d.jpg

Fig. : Use a scraper to clean old gasket material from the engine block's thermostat housing mating surface ...


db9a50c.jpg

Fig. : ... as well as the thermostat housing

continue...





21helpful
1answer

Change thermostat on gm 3400 v6

Drain coolant at the radiator drain. Remove air intake hose and MAF sensor assembly. remove throttle cable bracket and disconnect cable linkage. Remove throttle body bolts and disconnect coolant hoses to throttle body. Loosen heater hose pipe and remove heater hose from rear of pipe. Remove radiator hose from thermostat housing. Remove top thermostat housing bolt. Loosen and almost remove lower thermostat bolt. You will need to slide your wrench and hand under the exhaust crossover pipe to gain access. Loosen the bolt until you can remove the thermostat housing, it should be slotted to clear the bolt. Replace the thermostat and reassemble. Bleed cooling system using the two bleed screws (one on thermostat housing and the other on the passenger side of the engine where the heater hose pipe comes out above the water pump.
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