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Boy you have done everything I'd suggest to try,the only thing I can think of when you installed the thermostat did the housing holding it craft maybe a hairline just big enough to cause pressure problems, only other thing else is maybe you have a clog in a hose or in the radiator sorry that's all I got,other then the thermostat they sold you was junk one thing I'd try returning it and get a new one you never said it it was used or new
1 Remove the air intake duct hose from Mass Air Flow sensor. ( Air filter end) 2 Disconnect PCV hose 3 Remove air Intake adapter assy. From Throttle body 4 Drain Coolant. 5 Remove 2 bolt / studs from thermostat housing 6 Remove thermostat housing. 7 Remove thermostat. clean gasket and sealing surfaces 8 install new thermostat with new gasket/ seal 9 install thermostat housing torque bolt/Studs to 18 ft. lbs. 10 Reassemble the rest in reverse order 11 Fill coolant to proper level, check coolant level after running engine. Top off *** necessary when engine is cool.
Not always. If you have a KA24E (2.4L 4 cyl) engine, the thermostat is located where the lower hose connects to the engine. I have had to change mine. It's easiest to get to if you remove the power steering pump and set it to the side. The thermostat housing is directly below where the PS pump mounts.