Question about 1995 Dodge Caravan

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Broken bolt housing for thermostat gooseneck cover on intake mani

The bolt housing on the intake manifold for the thermostat gooseneck cover broke while drilling out sheered of bolt ,

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Hello, The only thing you can do is weld the broken area and the drill and tap the hole.
Go to http://www.durafix.com/ and they have a solution for you. Good luck and let me know how you make out.

Posted on Jan 21, 2009

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2005 elantra not an idiot but cannot find the thermastat to replace it is it well hidden followed all the large hoses HELPchipt


Remove the radiator hose from the thermostat housing cover by removing the band clamp that holds the hose to the cover. This is done with a Phillips screwdriver. Slide the band clamp back away from the housing and pull the hose off.


  • 2 Remove the two bolts that hold the thermostat housing cover to the top of the Elantra intake manifold with an adjustable wrench. The bolts will be reused. They should not be discarded.


  • 3 Remove the old gasket that was pressed between the intake manifold and the thermostat housing cover. It's a paper gasket and should pull off of the intake in one piece. Remove the thermostat from inside of the intake manifold by pulling up on it. The gasket and thermostat can be discarded.

  • 4 Place the new thermostat into the intake manifold of the Hyundai Elantra. The thermostat must be placed with the top sticking out of the intake manifold for it to work properly. Use the old thermostat to orientate the new one.

  • 5 Place a small amount of PVC gasket sealer around the thermostat on the base of the intake manifold. Allow the PVC to dry for ten minutes and then place the thermostat gasket on top of the gasket sealer. Place a small amount of PVC gasket sealer on top of the paper gasket and allow to dry for ten minutes.

  • 6 Place the thermostat housing cover onto the gasket and bolt it into place with the original bolts. You should see a small amount of PVC gasket sealer squeeze out between the housing and the intake. This is normal and it should be left in place. Once it dries, it will add additional seal protection and prevent leaking.

  • 7 Place the radiator hose back on to the thermostat housing cover and fix it into place by tightening the band clamp with a screw driver. Your Hyundai Elantra is now ready to drive again.

  • In case of a problem or clarification or my solution was insufficient, don't hesitate to post me a reply.

    If you are satisfied, rate my solution with the "thumbs" or (even better) add a testimonial.

    May 30, 2011 | Hyundai Elantra Cars & Trucks

    2 Answers

    How do i replace the thermostat


    Follow this steps on how you can replace the thermostat. First,Remove the radiator hose from the thermostat housing cover by removing the bandclamp that holds the hose to the cover. This is done with a Phillipsscrewdriver. Slide the band clamp back away from the housing and pull the hoseoff. Remove the two bolts that hold the thermostat housing cover to the top ofthe Elantra intake manifold with an adjustable wrench. The bolts will bereused. They should not be discarded. Remove the old gasket that was pressed between the intake manifoldand the thermostat housing cover. It's a paper gasket and should pull off ofthe intake in one piece. Remove the thermostat from inside of the intakemanifold by pulling up on it. The gasket and thermostat can be discarded. Placethe new thermostat into the intake manifold of the Hyundai Elantra. Thethermostat must be placed with the top sticking out of the intake manifold forit to work properly. Use the old thermostat to orientate the new one. Place a small amount of PVC gasket sealer around the thermostat onthe base of the intake manifold. Allow the PVC to dry for ten minutes and thenplace the thermostat gasket on top of the gasket sealer. Place a small amountof PVC gasket sealer on top of the paper gasket and allow to dry for tenminutes. Place the thermostat housing cover onto the gasket and bolt it intoplace with the original bolts. You should see a small amount of PVC gasketsealer squeeze out between the housing and the intake. This is normal and itshould be left in place. Once it dries, it will add additional seal protectionand prevent leaking. Place the radiator hose back on to the thermostat housing cover andfix it into place by tightening the band clamp with a screw driver. YourHyundai Elantra is now ready to drive again. Hope this info help you.

    Jan 25, 2011 | 2005 Hyundai Elantra

    1 Answer

    Need to replace the themostat


  • Remove the bolts that hold the thermostat housing onto the intake manifold of the MR2 with an adjustable wrench and pull up on the thermostat housing to remove it from the intake. The housing is still connected to the hose. Lift the thermostat housing and the hose up to drain the antifreeze back into the radiator.
  • 2 Remove the old thermostat from the hole inside of the intake manifold and replace it with a new one. Pull the thermostat gasket off of the top of the intake manifold and wipe the manifold clean with a towel.
  • 3 Place a bead of RTV gasket maker around the bottom edge of the thermostat housing and allow it to dry for 15 minutes. Place the thermostat housing back onto the intake manifold and bolt the housing back into place. Allow 15 more minutes of drying time and slightly tighten the bolts again. This will form a solid seal between the intake manifold and the thermostat housing.



  • Dec 23, 2010 | 1991 Toyota MR2

    1 Answer

    Need location of thermostate


    Removal & Installation 3.9L, 5.2L & 5.9L Engines 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 until level is below thermostat dod_trk_altbracket.gif

      • Support bracket located near rear of alternator (A/C Vehicles) dod_trk_releasebelttension.gif

      • Alternator drive belt by attaching a wrench to the pulley mounting bolt of the automatic tensioner, rotating the tensioner clockwise to release belt tension, and removing the belt:
      • Alternator mounting bolts, but do not remove any wiring at alternator
      • 4WD indicator lamp wiring harness (4WD vehicles)
      • Alternator and position aside WARNING
        When servicing constant tension hose clamps, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094). Always wear safety glasses when servicing constant tension clamps. Always replace constant tension clamps with the same numbered clamp.
      • Radiator hose clamp and upper radiator hose at thermostat housing and position wiring harness aside to gain access to thermostat dod_trk_59l_thermostat.gif

      • Thermostat housing mounting bolts, thermostat housing, gasket and thermostat
    To Install:
    1. Clean intake manifold and thermostat housing mating surfaces.
    2. Install or connect the following:
      • Thermostat (spring side down) into recessed machined groove on intake manifold
      • Gasket on intake manifold and over thermostat dod_trk_thermohousingposition.gif

      • Thermostat housing to intake manifold NOTE: The word FRONT is stamped on housing and must be placed towards front of vehicle.
      • 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:
      • Thermostat (spring side down) into recessed machined groove on timing chain cover
      • 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.
    prev.gif next.gif

    Aug 26, 2010 | 2001 Dodge Durango

    1 Answer

    Location of engine thermostat


    Removal & Installation 3.0L Engine To Remove:
    1. Before servicing the vehicle, refer to the precautions in the beginning of this section
    2. Drain the engine cooling system
    3. Remove or disconnect the following:
      • Air cleaner outlet tube
      • Hoses and remove the thermostat housing assembly
      • Bolts separate the housing and remove the thermostat and seal
    To Install:
    1. Install or connect the following:
      • New seal and thermostat. Torque bolts to 8 ft-lbs (11 Nm)
      • Hoses to assembly
      • Air cleaner outlet tube
    3.9L Engine To Remove:
    1. Before servicing the vehicle, refer to the precautions in the beginning of this section
    2. Drain the engine cooling system
    3. Remove or disconnect the following:
      • Intake manifold
      • Nuts and remove the hose bracket
      • Stud bolts
      • Lower radiator hose from the thermostat housing
      • Bolts and thermostat housing cover
      • Thermostat and seal
    To Install:
    1. Install or connect the following:
      • New seal and thermostat
      • Housing cover. Torque bolts to 8 ft-lbs (11 Nm)
      • Lower radiator hose to the thermostat housing
      • Stud bolts. Torque to 10 ft-lbs (13 Nm)
      • Hose bracket. Torque nuts to 89 in-lbs (10 Nm)
      • Intake manifold

    Aug 17, 2010 | 2000 Lincoln LS

    2 Answers

    Need to replace the intake manifold


    3.8L Engine (most common) Upper Intake Manifold To Remove:
    1. Drain the cooling system.
    2. Remove or disconnect the following:
      • Negative battery cable.
      • Fuel injector sight shield.
      • Air cleaner intake duct.
      • Right spark plug wires from the ignition control module and reposition.
    3. Relieve the fuel pressure.
    4. Remove or disconnect the following:
      • Fuel rail assembly.
      • Brake booster hose from the vacuum source manifold in the upper intake manifold.
      • Exhaust Gas Recirculation Valve (EGR) wiring harness heat shield nut, bolt and the EGR heat shield.
      • Throttle body support bracket upper bolt.
    5. Disconnect the electrical connectors from the following:
      • EVAP purge solenoid
      • Throttle Position (T/P) sensor
      • Idle Air Control (IAC) valve
      • Manifold Absolute Pressure (MAP) sensor
      • Mass Air Flow (MAF) sensor
      • EVAP purge solenoid vacuum line from the throttle body.
      • Accelerator and the cruise control cables with the bracket from the throttle body.
    6. Remove or disconnect the following:
      • Upper intake manifold bolts and stud.
      • Clean the upper intake manifold bolt threads.
    7. Remove or disconnect the following:
      • Upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
      • Upper-to-lower intake manifold carrier gasket from the upper intake manifold.
    8. If the upper intake manifold is being replaced, remove the following:
      • Throttle body assembly.
      • Manifold Absolute Pressure (MAP) sensor.
      • Positive Crankcase Ventilation (PCV) valve.
      • Vacuum source manifold.
    Upper intake manifold bolt torque sequence (3.8L engine) gm-03-38-530.gif

    To Install:
    1. If the manifold was replaced, install or connect the following:
      • Vacuum source manifold.
      • Positive Crankcase Ventilation (PCV) valve.
      • Manifold Absolute Pressure (MAP) sensor.
      • Throttle body assembly.
      • Upper-to-lower intake manifold carrier gasket to the upper intake manifold.
    2. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold. NOTE: Apply thread lock compound, to the bolt threads before assembly.
    3. Install or connect the following:
      • Upper intake manifold. Tighten the upper intake manifold bolts in sequence to 89 in lbs (10 Nm)
      • Accelerator and the cruise control cables with the bracket to the throttle body.
      • EVAP purge solenoid vacuum line to the throttle body.
    4. Connect the electrical connectors to the following:
      • Mass Air Flow (MAF) sensor
      • Manifold Absolute Pressure (MAP) sensor
      • Idle Air Control (IAC) valve
      • Throttle Position (T/P) sensor
      • EVAP purge solenoid
    5. Install or connect the following:
      • Throttle body upper support bracket bolt. Tighten the bolt to 89 in lbs (10 Nm)
      • EGR valve wiring harness heat shield, nut and the bolt. Tighten the nut and the bolt to 89 in lbs (10 Nm)
      • Brake booster hose to the vacuum source manifold.
      • Fuel rail assembly.
      • Right spark plug wires.
      • Air cleaner intake duct.
      • Fuel injector sight shield.
    6. Connect the negative battery cable.
    7. Fill the cooling system.
    8. Inspect for fluid or vacuum leaks.
    Lower Intake Manifold (W/O Supercharger) To Remove:
    1. Remove or disconnect the following:
      • Upper intake manifold.
      • Generator brace.
      • Drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe.
      • Exhaust gas recirculation EGR outlet pipe bolt from the lower intake manifold.
      • Radiator inlet hose from the water outlet housing.
      • ECT sensor electrical connector.
      • Right upper engine mount strut bracket.
      • Generator brace bracket bolts.
      • Generator brace bracket.
      • Lower intake manifold bolts.
      • Lower intake manifold.
      • Lower intake manifold seals.
      • Lower intake manifold gaskets.
    2. If replacing the lower intake manifold, Remove or disconnect:
      • Water outlet housing bolt and stud
      • Water outlet housing
      • Gasket and the thermostat.
      • ECT sensor.
    3. Inspect the flatness of inlet flanges.
    4. Clean the intake manifold mating surfaces.
    5. Clean the intake manifold bolts and bolt holes of adhesive compound.
    To Install:
    1. If removed, install the ECT sensor.
      • Tighten the ECT sensor to 18 ft. lbs. (25 Nm)
    2. If removed, install the thermostat, the gasket, and the water outlet housing.
    3. If removed, install the water outlet housing bolt and the stud.
      • Tighten the bolt and stud to 20 ft. lbs. (27 Nm)
    4. Install or connect the following:
      • Lower intake manifold gaskets. NOTE: Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
      • Lower intake manifold seals.
      • Lower intake manifold.
      • Lower intake manifold bolts.
      NOTE: Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed.
    5. Tighten the lower intake manifold bolts in sequence to 11 ft. lbs. (15 Nm) gmpc_v6_5.gif

    6. Install or connect the following:
      • Generator brace bracket.
      • Generator brace bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm)
      • Right upper engine mount strut bracket.
      • ECT sensor electrical connector.
      • Radiator inlet hose to the water outlet housing.
      • EGR outlet pipe to the lower intake manifold.
      • EGR outlet pipe bolt to the lower intake manifold. Tighten the bolt to 21 ft. lbs. (29 Nm)
      • Drive belt tensioner.
      • Generator brace.
      • Upper intake manifold.
    7. Inspect for leaks.
    Lower Intake Manifold (W/ Supercharger) To Remove:
    1. Disconnect the negative battery cable.
    2. Drain the cooling system.
    3. Remove the supercharger.
    4. Remove the thermostat housing.
    5. Remove the EGR pipe at the intake manifold.
    6. Disconnect the electrical connection at the temperature sensor.
    7. Remove the intake manifold and gaskets.
    NOTE: The coolant bypass tube will release from the intake manifold when the manifold is removed.
    To Install:
    1. Clean the gasket sealing surfaces.
    2. Install the intake manifold gaskets.
    3. Align the coolant bypass tube with the opening in the intake manifold and install the manifold. Tighten the bolts to 11 lb ft (15 Nm).
    4. Install the electrical connector to the temperature sensor.
    5. Install the EGR pipe to the intake manifold.
    6. Install the thermostat housing.
    7. Install the supercharger.
    8. Fill the cooling system.
    9. Connect the negative battery cable.

    Aug 05, 2010 | 1997 Pontiac Grand Prix

    1 Answer

    How to change the thermostat


    Alero, Grand Am 1999-2005 Thermostat - Removal & Installation 2.2L Engine
    1. If equipped with an automatic transaxle, remove the exhaust manifold, as outlined in this section.
    2. Drain the cooling system.
    3. Remove the thermostat housing to water pump feed pipe bolts.
    4. Remove the thermostat housing to water pump feed pipe.

      d1db35e.jpg
      Fig. Thermostat mounting-2.2L engine
    5. Remove the thermostat.

    To install:
    1. Install the thermostat.
    2. Install the thermostat housing to water pump feed pipe.
    3. 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).
    4. If equipped with an automatic transaxle, install the exhaust manifold, as outlined in this section.
    5. Fill the cooling system.

    3.1L Engines
    1. Disconnect the negative battery cable.
    2. Drain the cooling system to a level below the thermostat housing.
    3. Remove the air cleaner assembly.
    4. Disconnect the surge tank line from the thermostat housing.
    5. Remove thermostat housing-to-intake manifold attaching bolt and nut, then remove the housing.
    6. Remove the thermostat.

    To install:
    1. Clean all gasket surfaces completely.
    2. Insert the thermostat in the intake manifold.
    3. Attach the thermostat housing to the intake manifold.
    4. Install the mounting bolt and nut. Tighten to 18 ft. lbs. (25 Nm).
    5. Install the air cleaner assembly.
    6. Connect the surge tank line to thermostat housing.
    7. Refill the cooling system.
    8. 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.
    9. Install the radiator cap, making sure the arrows line up with the overflow tube.

    3.4L Engine
    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
    7. Clean the mating surfaces.

    To install:
    1. Install the thermostat and housing outlet.
    2. Install the thermostat housing bolts. Tighten the thermostat housing bolts to 18 ft. lbs. (25 Nm).
    3. Install exhaust crossover pipe.
    4. Connect the surge tank line fitting to the coolant outlet. Tighten the fittings to 15 ft. lbs. (21 Nm).
    5. Install the air cleaner.
    6. Fill the cooling system.
    7. Inspect the system for leaks.
    Hope this help (remember comment and rated this).

    Apr 04, 2010 | 1999 Oldsmobile Alero

    1 Answer

    How do I install a new thermostat?


    Explorer Thermostat LocationHere is advice for finding the thermostat:

    • Follow the upper radiator hose from the radiator to the engine and there is a housing that houses the thermostat. Take it off and when you reinstall the thermostsat, make sure the spring goes toward the engine.

    • The thermostat is located on the motor block under the three bolt flang that the top rediator hose connects to. Remove the three 10MM bolts and the thermostat can be removed for replacement.

    How to Change an Explorer Thermostat
    • 1. Remove the air cleaner air duct from the throttle body and air cleaner.
    • 2. Follow the upper radiator hose to the engine to locate the thermostat housing. The housing is located at the front of the intake manifold.
    • 3. Loosen the hose clamp, then detach the hose from the fitting. This can be difficult. If it's stuck, grasp with a pair of adjustable pliers and twist to break the seal. Then pull it off.
    • 4. Remove the bolts and detach the housing cover. Be prepared some coolant may leak out as the gasket seal is broken. Remove the thermostat.
    • 5. Install the new o-ring onto the thermostat (no gasket is needed) and install the thermostat into the intake manifold with the spring side pointing toward the engine.
    • 6. Make sure the air release valve is in the up 12 o'clock position. Install housing cover and bolts. Reattach the hose fitting and tighten the hose clamp. Fill the cooling system with a 50/50 mix of coolant and water, and burp the system.

    Nov 05, 2009 | 2001 Ford Explorer Sport

    1 Answer

    Intake manifold sealant repair now leaking maybe oil? coolant b4


    You need to remove the thermostat housing again. Then you will have to extract the bolts you broke off. You will need to drill and tap them so you can use an easy out to remove the broken bolts from the threads. Then you can clean up both mating surfaces and replace the gasket and the thermostat. Check to make sure you did not crack the thermostat housing or you may have another leak when finished. They are usually aluminum and break easily if too much pressure is applied or they are corroded and weak.

    Feb 25, 2009 | 1999 Ford Taurus

    1 Answer

    On our 1996 ford taurus the return line connection broke off.


    IF this Hose Nipple is A Casted Aluminum or iron and is "part of" the Thermostat Housing Simply ( Replace T-Stat Housing itself),,,, If it is Part of the INTAKE MANIFOLD Ouch!! Replace Intake manifold. I Hope this Sheds Light on your Problem so as to Lead to A Good Repair for your Vehicle, If this does help
    'in any way" PLEASE don't forget to RATE me as to Your Discretion








    Jan 11, 2009 | 1996 Ford Taurus

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