We broke the lip of the place where you screw the radiator cap on - I think it's called the water outlet housing. Coincidentally need to replace the thermostat. I've searched the world over for the water outlet for a 2.4L and can only find one that fits 2.0 - does anyone know if it's called something else for my model.
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Remove the water hose, take off the two bolts holding the housing, bang off sideways if stuck and remove the housing, replace gasket after carefully scraping off all residue of last one and reinstall housing and hose. And properly refill the radiator with coolant.
Remove radiator cap and run engine till thermostat opens - then add water till it overflows and then put on cap and tighten. U done!
Firstly, disconnect the negative battery cable before draining the cooling system into a suitable container. Then reposition the hose clamp from water inlet pipe. Remove radiator outlet hose from water inlet pipe. Also, reposition the hose clamp from radiator. Finally, remove the radiator outlet hose from radiator and vehicle. To re-install another one, simply reverse the procedure.
Find the location where the upper radiator hose connects to
the intake manifold of the engine by tracing it from the radiator to thermostat intake housing bolted to the intake.
Remove the radiator hose from the thermostat intake housing
by loosening the band clamp that secures it into place. With the clamp
loosened, pull the hose off the housing.
Remove the two bolts that secure the housing to the intake manifold and then lift the housing off the intake.
Lift the thermostat out of the intake manifold and place the
new thermostat into the hole. The end of the thermostat with the pin
protruding from it sticks out of the intake manifold.
Lift the thermostat intake housing gasket off the intake manifold and place the new one onto the intake manifold.
Place the thermostat intake housing onto the intake manifold and bolt it into place. Reconnect the hose using the band clamp.
the Dodge onto a set of front-end ramps and secure the parking break.
Allow adequate time for the radiator fluid to cool down. Thirty minutes
is usually adequate.
Loosen the petcock on the lower right hand side of the
radiator and drain all of the radiator fluid into a drain pan. Close the
petcock once drained.
Trace the lower radiator hose to the location where the hose
connects to the engine block. The metal housing the hose connects to is
the lower thermostat outlet. Remove the hose from the outlet by
loosening the band clamp and then by pulling the hose off the outlet. Be
careful--some fluid will drain from the hose.
Remove the two bolts that secure the thermostat outlet to the engine block and pull the thermostat outlet off the block.
Discard the O-ring inside the bottom edge of the thermostat outlet and place a new one into the outlet.
Pull the thermostat out of the engine block and replace it
with a new one. The end with the pin protruding from it sticks out of
the engine block.
Place the thermostat outlet onto the engine block and secure
it into place. Reattach the lower radiator hose with the band clamp.
Open the radiator filler cap located on top of the radiator
and fill the radiator with the fluid previously drained from the system.
Yes and no, at most auto parts stores they usually use the term "water outlet" to refer to the upper portion, the lid if you will, of the thermostat housing. This is the part that the upper radiator hose connects to. It looks like this:
Most times shops and parts stores use these terms interchangeably though. The thermostat in your car sits in whats called a water box, which the coolant temperature sensor connects into and is capped in by the housing/water outlet. I would just ask, if you are being told by a shop, if you just need the piece that connects to the radiator hose and bolts over the thermostat or if you need the the outlet and the water box.
DRAIN COOLANT LEVEL DOWN BELOW THERMOSTAT.PLACE DRAIN PAN UNDER VECHICLE TO CATCH ANTIFREEZE.WHEN DONE PUT ANTIFREEZE SAFE PLACE FROM KIDS AND ANIMALS.WHEN DONE DRAINING SOME ANTIFREEZE.FOLLOW RADIATOR HOSE TO TOP OF INTAKE TO THERMOSTAT HOUSING. LOOSEN HOSE CLAMP REMOVE RADIATOR HOSE FROM THERMOSTAT HOUSING.THEN LOOSEN HOUSING BOLTS.REMOVE THERMOSTAT HOUSING AND THERMOSTAT.CLEAN BOTH THE THERMOSTAT HOUSING SURFACE AND INTAKE SURFACE YOU CAN USE ACETATE OR BRAKE CLEANER AND SCOTCH BRITES ROLL OF CLEAN PAPER TOWEL. AFTER CLEANING HOUSING AND INTAKE SURFACE MAKE SURFACE CLEAN SMOOTH FROM THE DEBRIS WHEN DONE. TAKE THERMOSTAT PUT GASKET SEALER ON BOTH SIDES OF GASKET PUT GASKET TO THERMOSTAT HOUSING MAKE SURE GASKET AND THERMOSTAT HOUSING HOLES ALIGN CORRECTLY.NOW PLACE NEW THERMOSTAT IN PLACE IN THE INTAKE.MAKE SURE THERMOSTAT SPRING END GOES TOWARD ENGINE FACING DOWN.THEN INSTALL THERMOSTAT HOUSING WITH GASKET TO THE INTAKE.TORQUE THERMOSTAT HOUSING BOLTS TO 20 FT LBS.WAIT 1 HOUR BEFORE POURING ANTIFREEZE BACK IN THE COOLANT SYSTEM GIVE THERMOSTAT GASKET SEALER LITTLE TIME TO CURE.SO YOU WONT HAVE COOLANT LEAKS.NOW IF THERMOSTAT HAS THE LARGE O- RING ON IT YOU DONT HAVE A THERMOSTAT HOUSING GASKET THE THERMOSTAT O- RING IS THE SEAL THAT HOLDS COOLANT INSTEAD OF GASKET.WHEN THERMOSTAT AND HOUSING IN PLACE.INSTALL RADIATOR HOSE TO THERMOSTAT HOUSING TIGHTEN HOSE CLAMP.THEN FILL RADIATOR BACK UP WITH THE COOLANT YOU DRAIN OUT.START VECHICLE UP. THEN CHECK FOR LEAKS.
Alero, Grand Am 1999-2005
Thermostat - Removal & Installation
If equipped with an automatic transaxle, remove the exhaust
manifold, as outlined in this section.
Drain the cooling system.
Remove the thermostat housing to water pump feed pipe bolts.
Remove the thermostat housing to water pump feed pipe.
Fig. Thermostat mounting-2.2L engine
Remove the thermostat.
Install the thermostat.
Install the thermostat housing to water pump feed pipe.
Install the thermostat housing to water pump feed pipe bolt.
Tighten the thermostat housing to water pump feed pipe bolt to 89 inch
lbs. (10 Nm).
If equipped with an automatic transaxle, install the exhaust
manifold, as outlined in this section.
Fill the cooling system.
Disconnect the negative battery cable.
Drain the cooling system to a level below the thermostat housing.
Remove the air cleaner assembly.
Disconnect the surge tank line from the thermostat housing.
Remove thermostat housing-to-intake manifold attaching bolt and
nut, then remove the housing.
Remove the thermostat.
Clean all gasket surfaces completely.
Insert the thermostat in the intake manifold.
Attach the thermostat housing to the intake manifold.
Install the mounting bolt and nut. Tighten to 18 ft. lbs. (25 Nm).
Install the air cleaner assembly.
Connect the surge tank line to thermostat housing.
Refill the cooling system.
Connect the negative battery cable, remove the radiator cap, then
start the engine. Allow the engine to run with radiator cap removed,
until the upper radiator hose becomes hot (thermostat open). With the
engine idling, add coolant to the radiator until the level is up to the
bottom of the filler neck.
Install the radiator cap, making sure the arrows line up with the
Drain the cooling system.
Remove the air cleaner.
Remove exhaust crossover pipe.
Disconnect the surge tank line fitting from the coolant outlet.
Remove the thermostat housing to intake manifold bolts.
Remove the thermostat housing outlet and thermostat
Clean the mating surfaces.
Install the thermostat and housing outlet.
Install the thermostat housing bolts. Tighten the thermostat
housing bolts to 18 ft. lbs. (25 Nm).
Install exhaust crossover pipe.
Connect the surge tank line fitting to the coolant outlet. Tighten
the fittings to 15 ft. lbs. (21 Nm).