Question about GMC K1500

2 Answers

6.5 Diesel Thermostat Housing Bolt Access: Gentlemen, I have marveled at the idiocy of the alternator bracket housing, cursed long and loud over the near psychosis of the water pump mounting, and have detoured into the perplexing case of the gigantic Torx bolt on the belt tensioner. I am now faced with the lower bolts on the dual thermostat housing. How, pray tell, does one remove these hidden treasures. I am but a simple shade tree novice, raised on the silly old 2 bolt thermostat housing. What to I have to remove, disassemble or otherwise warp into hyperspace to achieve the monumentally simple task (yeah, right) of replacing the thermostats on this vehicle?

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  • andylit Feb 26, 2010

    Thanks Ben, but no way. That does not appear to be possible. Again, the question is, what do I have to remove to do this job. I do NOT want to start tearing stuff off the motor on a hit or miss basis. Can I do this job by removing the Turbo cover? Or the turbo cover and other stuff?

  • andylit Feb 26, 2010

    I'll take it, but be aware that the bottom driver side bolt can only be accessed easily if you remove the A/C compressor. Otherwise, you need to come in with a flex socket from the rear. In my case, it cannot be done because the bolt has been in place for 250,000 miles. Breaker bar doesn't work on an angle with a flex socket, or at least let's say I am not going to destroy a flex socket in the attempt. no more GM products for me, EVER.

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GM Full-Size Trucks 1988-1998 Repair Information
Thermostat - REMOVAL & INSTALLATION

Diesel Engines
1988-95 models

  1. Remove the upper fan shroud.
  2. Drain the cooling system to a point below the thermostat.
6.5 Diesel Thermostat Housing Bolt - 1644db1.jpg

Fig. 9: Thermostat housing-6.2L engines, R/V series

661442f.jpg

Fig. 10: Thermostat housing-6.2L and 6.5L diesel engines-1988-95 C/K series
  1. Remove the engine oil dipstick tube brace and the oil fill brace.
  2. Remove the upper radiator hose.
  3. Remove the water outlet.
  4. Remove the thermostat and gasket.
  5. Installation is the reverse of removal.
  6. Use a new gasket coated with sealer, Make sure that the spring end of the thermostat is in the engine. Tighten the bolts to 35 ft. lbs. (47 Nm) on 1988-91 models and 31 ft. lbs. (42 Nm) on 1992-95 models.

1996-98 Models

  1. Drain the cooling system to a point below the thermostat.
  2. Disconnect the upper radiator (inlet) hose from the thermostat outlet.
  3. Ufasten the thermostat housing bolt and stud, then remove the housing.
  4. Remove the gasket and the thermostat.
  5. Clean any remaining gasket from the thermostat hosing mating s6.5 Diesel Thermostat Housing Bolt - bdc4644.jpgpan>
bdc4644.jpg

Fig. 11: Exploded view of the thermostat assembly components-1996-98 diesel engines

To install:

  1. Place the thermostat into position in the housing, then install the gasket.
  2. Install the thermostat housing, the bolt and the stud. Tighten the bolt and stud to 31 ft. lbs. (42 Nm).
  3. Attach the upper radiator (inlet) hose to the thermostat outlet.
  4. Fill the cooling system.
  5. Start the engine with the radiator cap still removed, until the upper radiator hose is hot (this means the thermostat is open).
  6. With the engine idling, add coolant until the coolant level reaches the bottom of the filler neck.
  7. Instal the radiator cap making sure the arrows line up with the overflow tube and check for coolant leaks.
continue...

Posted on Feb 26, 2010

  • ZJ Limited
    ZJ Limited Feb 26, 2010

    f
    Thermostat Housing Crossover - REMOVAL & INSTALLATION
    (This is found on the 6.2 and 6.5L diesel engines only)




    CAUTION

    Never open, service or drain the radiator or cooling system when
    hot; serious burns can occur from the steam and hot coolant. Also, when
    draining engine coolant, keep in mind that cats and dogs are attracted
    to ethylene glycol antifreeze and could drink any that is left in an
    uncovered container or in puddles on the ground. This will prove fatal
    in sufficient quantities. Always drain coolant into a sealable
    container. Coolant should be reused unless it is contaminated or is
    several years old.







    1. Drain the cooling system.


    2. Remove the engine cover.


    3. Remove the air cleaner and CDR valve.




    Fig. 1: Thermostat housing crossover-1988-91 R/V series











    Fig. 2: Thermostat housing crossover-1988-96 C/K series










    Fig. 3: Thermostat housing crossover-1997-98 C/K series






    1. Remove the air cleaner resonator and bracket.


    2. Remove the upper fan shroud.


    3. Remove the upper alternator bracket.


    4. Remove the bypass hose.


    5. Remove the upper radiator hose.


    6. Disconnect the heater hose.


    7. Remove the attaching bolts and lift out the crossover.


    To install:



    1. Thoroughly clean the mating surfaces.


    2. Position the crossover, using new gaskets coated with sealer.


    3. Install the attaching bolts and tighten them to 35 ft. lbs. (47
      Nm) on 1988-91 engines, or 31 ft. lbs. (42 Nm) on 1992-98 engines.



    4. Connect the heater hose.


    5. Install the upper radiator hose.


    6. Install the bypass hose.


    7. Install the upper alternator bracket.


    8. Install the upper fan shroud.


    9. Install the air cleaner resonator and bracket.


    10. Install the air cleaner and the CDR valve.


    11. Install the engine cover.


    12. Fill the cooling system.

    Hope help with this.


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  • Master
  • 389 Answers

Hello, my name is Ben. I understand your frustration with this 4 bolt housing. After you remove the upper radiator hose, take a long extension and work from the rear of the engine. It's difficult but it can be done. And of course be very careful with re-installing those bolts so as to not cross thread them. Clean the gasket surfaces real good, obviously you do not want to go through this again. I hope this helps, good luck.

Posted on Feb 26, 2010

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a108892a.gif

Section 03-01D: Diesel Engine, 7.3L V-8 1992 Bronco/Econoline/F-Series Workshop Manual
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a119101a.gif

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1 Answer

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just click this link directly
http://www.2carpros.com/maintenance/car_safety_inspection.htm
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Unplug the electrical connector from the alternator.
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Remove the alternator from the vehicle.
To Install:
Position the alternator to the engine.
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Install the outboard alternator bolt into the alternator housing.
Install the inboard alternator bolt and then finger-tighten the outboard bolt.
Install the idler pulley and idler pulley bolt.
Tighten the bolts in the following torque sequence:
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Install the water inlet and thermostat housing and the radiator hose, observing the following:
Inspect and clean the mating surfaces on the thermostat cover and its mounting surface on the engine.
Use RTV Sealer GM #1052366 or equivalent on the mounting bolts since the threaded openings are open to the cooling system and the torque requirement is low.
Install the water inlet and thermostat housing and tighten the bolts to 80 inch lbs. (9 Nm).
Connect the surge tank inlet hose to the water inlet housing.
Connect the heater hose to the water inlet housing.
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This will help. Thanks please keep updated. please do rate the solution positively .thank you for using fixya.

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1 Answer

How to change a thermastat 1994 ford escort with a 1.9 engine


1.9L Engine

CAUTION Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.
  1. Disconnect the negative battery cable.
  2. Drain the cooling system.
  3. Remove the air intake tube, crankcase breather and PCV hose.
  4. Remove the ignition coil pack and bracket.
  5. Remove the upper radiator hose.
  6. Remove the ignition coil pack bracket.
  7. Unfasten the heater hose inlet tube bracket bolt and remove the heater hose inlet tube from the thermostat housing.
  8. Remove the three thermostat housing attaching bolts, then remove the thermostat housing and gasket.
b2d5ac4.jpg

Fig: Remove the ignition coil pack


b5ad3b2.jpg

Fig. : Detach the air intake tube, crankcase breather and PCV hose


3a3c4dd.jpg
Fig. : Disconnect the upper radiator hose from the radiator


63b3b74.jpg
Fig. : Unfasten the ignition coil pack bracket upper bolts...

076a94a.jpg

Fig. : ...and the lower bracket bolt, then remove the bracket

f656bf8.jpg

Fig. : Unfasten the heater hose inlet tube bracket bolt (arrow)

314321c.jpg

Fig: Unfasten the heater hose inlet tube-to-thermostat housing clamp


3204281.jpg
Fig.: Disconnect the hose inlet tube from the thermostat housing

5dc1ba9.jpg

Fig. : Unfasten the three thermostat housing bolts


2fb60e5.jpg

Fig. Separate the thermostat housing from the engine block


6f1527f.jpg

Fig. : Remove the thermostat from the housing


e33ea6d.jpg

Fig. : Use a scraper to clean old gasket material from the engine block's thermostat housing mating surface ...


db9a50c.jpg

Fig. : ... as well as the thermostat housing

continue...





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1 Answer

Change thermostat on gm 3400 v6


Drain coolant at the radiator drain. Remove air intake hose and MAF sensor assembly. remove throttle cable bracket and disconnect cable linkage. Remove throttle body bolts and disconnect coolant hoses to throttle body. Loosen heater hose pipe and remove heater hose from rear of pipe. Remove radiator hose from thermostat housing. Remove top thermostat housing bolt. Loosen and almost remove lower thermostat bolt. You will need to slide your wrench and hand under the exhaust crossover pipe to gain access. Loosen the bolt until you can remove the thermostat housing, it should be slotted to clear the bolt. Replace the thermostat and reassemble. Bleed cooling system using the two bleed screws (one on thermostat housing and the other on the passenger side of the engine where the heater hose pipe comes out above the water pump.

Jan 23, 2009 | 2003 Pontiac Montana

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