Question about 2001 Mercury Villager

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2001 villager,is the inner thermostat housing replaceable or is it one with manifold?The upper front bolt ear has broken off so now cant seal the housing.

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  • Mercury Master
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Posted on Dec 03, 2010

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1 Answer

Do I have to take the top in take manafold off to tighten the lower intake manafold on a 1993 buick regal 3.8 L engine?


Yes you do, the following info explains the necessary procedure.



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  1. Properly relieve the fuel system pressure.
  2. Disconnect the negative battery cable. Place a clean drain pan under the radiator, open the drain **** and drain the cooling system.
  3. Remove the air cleaner assembly and the fuel injector sight shield.
  4. Disconnect the cables from the throttle body and mount bracket.
  5. Remove the coolant recovery reservoir.
  6. Remove the inner fender electrical cover on the right side.
  7. Remove the right rear crossover pipe heat shield.
  8. Disconnect the fuel lines from the fuel rail and from the cable bracket.
  9. Remove the alternator and brace.
  10. Remove the throttle body cable mounting bracket with the vacuum lines and disconnect the vacuum lines.
  11. Tag and detach the electrical connections at the throttle body and both banks of fuel injectors.
  12. Disconnect the vacuum hoses from the canister purge solenoid valve and transaxle module and intake connection.
  13. Unbolt the power steering pump and move forward. DO NOT disconnect the fluid lines.
  14. Tag and disconnect the spark plug wires position lay aside.
  15. Disconnect the coolant bypass hose from the intake manifold.
  16. Remove the solenoid valve mounting bracket and power steering support brace from the intake manifold.
  17. Disconnect the heater pipes from the intake and front cover.
  18. Remove the alternator support brace from the intake.
  19. Disconnect the upper radiator hose from the housing.
  20. Remove the thermostat housing and thermostat from the intake.
  21. Detach the electrical connector from the temperature sensor and sensor switch.
  22. Unfasten the intake manifold bolts, then remove the manifold as an assembly. Remove and discard the gaskets.
  23. If separating the upper manifold from the lower, proceed as follows:
  24. Remove the fuel rail and fuel injectors.
  25. Detach the coolant sensor switch.
  26. Remove the manifold end cap cover.
  27. Remove the upper intake manifold and throttle body assembly from the lower manifold. Remove and discard the gaskets. To install:
  28. Thoroughly clean all gasket mating surfaces.
  29. If replacing the upper manifold, proceed as follows:
  30. Apply a 1⁄16 in. bead of Loctite® Instant Gasket Eliminator 51845 or equivalent to the lower manifold mating surface. Make sure to circle all bolt holes.
  31. Carefully lower the upper manifold and throttle body assembly onto the lower manifold.
  32. Tighten the upper manifold retaining bolts to 19 ft. lbs. (26 Nm).
  33. Install the manifold end cap cover and the coolant sensor switch.
  34. Install the fuel injectors and rail to the manifold assembly.
  35. Clean the mating surfaces and install the intake manifold gaskets and seals. Apply sealer to the ends of the of the intake manifold seals.
  36. Position the intake manifold and apply a suitable thread lock compound to the bolt threads. Tighten the retaining bolts to 88 inch lbs. (10 Nm), twice, in the sequence shown in the accompanying figure.
  37. Attach the electrical connector to the temperature sensor and sensor switch.
  38. Install the thermostat housing and thermostat with a new gasket.
  39. Connect the alternator support brace to the intake.
  40. Install the solenoid valve mounting bracket and power steering support brace to the intake manifold.
  41. Connect the heater pipes to the intake and front cover.
  42. Attach the coolant bypass hose to the intake manifold.
  43. Install the power steering pump support bracket and tighten to 37 ft. lbs. (50 Nm).
  44. Install the spark plug wires on both sides.
  45. Install the belt tensioner pulley and tighten to 33 ft. lbs. (45 Nm).
  46. Install the power steering pump.
  47. Connect the vacuum hoses to the canister purge solenoid valve and transaxle module and intake connection.
  48. Attach the electrical connections at the throttle body and both banks of fuel injectors.
  49. Install the alternator and brace.
  50. Connect the throttle body cable mounting bracket with the vacuum lines.
  51. Install the right rear crossover pipe heat shield.
  52. Install the cables to the throttle body.
  53. Connect the fuel lines to the fuel rail and mount bracket.
  54. Install the inner fender electrical cover on the right side.
  55. Install the coolant recovery reservoir and upper radiator hose. Fill the cooling system.
  56. Install the air cleaner assembly and the fuel injector sight shield.
  57. Connect the negative battery cable.

Jan 31, 2011 | 1993 Buick Regal

1 Answer

Need to change engine thermostat on 2002 saturn vue. would like diagrams on how to and what to look for.


2.2L Engine To Remove:
  1. Drain the cooling system.
  2. Remove the exhaust manifold heat shield.
  3. Remove or disconnect the following:
  4. Thermostat housing to water pump feed pipe chevy_cav_02-04_tstat.gif
  5. Remove the thermostat cover bolts from the thermostat housing.
  6. Remove and discard the thermostat housing O-ring.
  7. Thermostat assembly saturn-03-22-4279.gif
  8. Twist the water feed pipe while pulling to remove it from the water pump. Remove the water pipe from the water pump assembly.
  9. Remove and discard the seals from the water pipe.
  10. Remove the inner thermostat sleeve.
  11. Remove the thermostat assembly.
To Install:
  1. Install the thermostat cartridge into the thermostat housing while aligning the cartridge tangs up with the thermostat housing bolt holes. This will assure the inner sleeve can be completely installed.
  2. Align and insert the inner sleeve notch into the thermostat housing. If the inner sleeve notch is not properly positioned, the sleeve will not completely seat into the housing.
  3. The water feed pipe seals can be slightly lubricated with silicone gel to aid during installation. Install a new O-ring on the water pipe.
  4. Position the water pipe into the water pump assembly.
  5. Seat the water feed O-ring by pushing and twisting toward the water pump. Take care not to tear or damage the O-ring.
  6. Install the thermostat housing cover to the water pipe. The water feed pipe has a locating tab to assure proper alignment.
  7. Install a new thermostat housing cover seal into the recess groove.
  8. Position the thermostat housing cover into position.
  9. Install the thermostat housing cover bolts and tighten bolts to (89 in-lb 10 Nm).
  10. Install the exhaust manifold heat shield.
  11. Fill the cooling system.

Dec 24, 2010 | 2002 Saturn VUE

3 Answers

I need to find the truck termostat, where is it?


The thermostat is located in the front of the intake manifold under the thermostat housing, and follow the upper radiator hose over to where it connects to the engine on the intake manifold and that will be the thermostsat housing. remove the upper radiator hose from the thermostsat housing and remove the ground wire if there is one attaced to one of the two thermostat housing studs, and then remove the two studs/bolts from the thermostat housing and then remove the thermostat from the intake manifold. Be sure to replace the thermostat correctly and here is an image to help assist you.


b932050.jpg

Sep 10, 2010 | 1997 Chevrolet C1500

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.
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Aug 26, 2010 | 2001 Dodge Durango

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

Timing belt removal 94 mercury villager


Hi, Disconnect battery ground cable, then drain coolant. Remove accessory drive belts. Remove A/C compressor drive belt idler pulley (tensioner) bolts, then idler pulley (tensioner). Remove upper radiator hose bracket bolt. Loosen two upper radiator hose clamps, then remove upper hose and bracket. Remove coolant bypass hose between thermostat housing and intake manifold coolant outlet. Disconnect main wiring harness from upper front cover (timing belt) cover, then remove eight upper timing belt cover bolts, then the upper cover, Fig. 20. Raise and support vehicle. Remove right front wheel and tire assembly and splash shield. Use strap wrench tool No. D85L-6000-A, or equivalent, to hold water pump pulley while removing water pump pulley bolts. Remove water pump pulley from water pump. Remove crankshaft pulley. Remove five lower timing belt cover attaching bolts and the cover. Rotate crankshaft in a clockwise direction to align crankshaft and camshaft sprocket timing marks, Fig. 21. If timing belt is to be reused, mark direction of rotation. Loosen timing belt tensioner nut, then remove timing belt. CAUTION: With timing belt removed, avoid turning camshaft or crankshaft. If movement is required, exercise extreme caution to avoid valve damage caused by piston contact.
Take care

Jul 24, 2010 | 1995 Mercury Villager

1 Answer

How does the thermostat go in. Tip up or down?


Thermostat - REMOVAL & INSTALLATION

WARNING Most cooling system hoses use "constant tension" hose clamps. When removing or installing, use a tool designed for servicing this type of clamp. The clamps are stamped with a letter or number on the tongue. If replacement is necessary, use only an OEM clamp with a matching ID.
CAUTION Always wear safety glasses when servicing contact tension clamps.
  1. Locate the thermostat. This is located in a housing on the engine side of the upper radiator hose for all engines except the 4.7L. On the 4.7L engine, the thermostat is located on the engine side of the lower radiator hose.
  2. Disconnect the negative battery cable (both batteries on diesels).
  3. Drain the engine coolant from the block until the level is below the thermostat.
  4. On V-10 engines, remove the support rod.
  5. On most V-6 and V-8 models, the alternator must be removed or repositioned for access to the thermostat housing.
  6. Remove the radiator hose from the thermostat housing.
  7. Disconnect any sensors fitted to the thermostat housing.
  8. Remove the retaining bolts from the thermostat housing. Note the lengths and location of each bolt for ease of installation.
  9. Remove the thermostat housing, thermostat, and gasket, if fitted.
  10. Note the relative positions of all components, especially gaskets and seals. Note the orientation of the thermostat in the housing.
To install:
  1. Be sure the new thermostat is the correct one for your engine.
  2. On V-10 engines, note that there is a rubber lip-type seal with a metal shoulder pressed into the intake manifold beneath the thermostat. The thermostat should fit snugly in the seal.
  3. Clean the gasket or seal mating surfaces.
  4. Paper gaskets must be replaced.
  5. Install the thermostat, gasket or seals.
  6. Install the thermostat housing on the engine.
NOTE The thermostat housing may have the word FRONT on it (3.9L, 5.2L, 5.9L); this goes towards the front of the vehicle.
  1. Be sure all components are properly seated before tightening.
  2. Tighten the housing bolts to 18 ft. lbs. (24 Nm). Fasteners should be tightened evenly to avoid leaks or damage.
  3. Reinstall the radiator hose onto the housing.
NOTE Ensure that you have secured the system drain plug(s) before refilling with coolant.
  1. Refill the radiator with a proper coolant mixture.
  2. Connect the negative battery cable(s).
  3. Start the engine and bleed the cooling system. Refer to "GENERAL INFORMATION AND MAINTENANCE."
  4. Ensure that the thermostat is operational (by checking the upper radiator hose for warmth), and that there are no leaks.

2f9dfd0.jpg

Fig. Thermostat assembly (2.5L). Note bolt lengths and locations


39f1d0f.jpg

Fig. On 3.9L, 5.2L, and 5.9L (gas) engines, the gasket goes above the thermostat

8fa75d6.jpg

Fig. On the 4.7L engine, the thermostat is at the bottom of the engine

6509cfa.jpg

Fig. V-10 thermostat assembly

4b8f531.jpg

Fig. Late model diesel thermostat assembly-2000 models


baf9b12.jpg


Fig. Removing the thermostat from the manifold-typical


Hope helps (remember comment adn rated this).

Jun 24, 2010 | 2000 Dodge Durango

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

5 Answers

Where exactly is the thermostat located on 1999 chevy blazer 4.3 vortec


follow your upper radiator hose to the motor. where it goes in is the thermostate housing, 2 bolts and it comes off

Nov 03, 2009 | 1999 Chevrolet Blazer

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

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