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Thermostat Replacement

 
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  #1 (permalink)  
Old 20 Feb 2010, 01:45 pm
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Default Thermostat Replacement

'03 Touring w/ std 2.4 bought new for wife but pushing 100k appears to be leaking at the thermo gasket. Obviously a tight place to get to. Looks like the plastic fuel injector/cowl/manifold thing (I don't know what it's technically called) should be removed to get better access. I'm assuming, just glancing, that there are two main bolts holding it into the injector assembly, and two holding it into the lower manifold (which doesn't need to be removed). Then complete access can be had to the gooseneck assembly all the way into the upper hose.

1) Is this correct?
2) Before I start something simple that turns into a nightmare, is there anything extra I need to know?
3) What temp thermostat should I use, live Charlotte area where its not excessively hot or cold)?
4) While I'm there should I replace the hose as well?
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Old 20 Feb 2010, 02:06 pm
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Default Re: Thermostat Replacement

Note, after closer inspection, 3 bolts at the FI and 5 where the cowl goes into the manifold.
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Old 20 Feb 2010, 05:11 pm
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Default Re: Thermostat Replacement

Got it all out, all in, then it leaked.
Am doing it a second time. Any suggestions?
That type thermo is slightly different from anything I've seen so it must rely on the rubber gasket squashing to seal.
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Old 20 Feb 2010, 07:50 pm
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Default Re: Thermostat Replacement

Make sure the thermostat is facing the right way up and it should fit into a recess thats built into the lower housing. The torque specs for the upper part of the housing are 110 in-lbs.

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Old 20 Feb 2010, 08:48 pm
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Default Re: Thermostat Replacement

Many thanks.
I had to use a dab of Permatex to hold the thermo in position while put it back in.
Think I got it now (after over torquing one of the 6mm bolts and breaking it, extracting it, and putting in a news one).
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