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thermostat and coolant temp sensor replacement, take 2
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Posted by jeff in MD (more from jeff in MD) on Mon, 11 Jan 2010 05:14:43 Share Post by Email
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I replaced the thermostat and coolant temperature sensor on my 2003 Aero yesterday, for the second time. I did it the first time back in February 2007 at 67k. The car now has 126k. Looking forward to doing it again at 190k or so :p

It had the typical symptoms - slow to warm up, never getting up to full temp, CEL code for engine temp out of range. I orderd the parts from eEuroparts, OEM for ~$35 total.

Most of the directions you'll see for this job indicate to drain the coolant first. I just put some old towels under the car and started taking things apart. I collected as much as I could with the towels and the rest with paper towels. This seemed like less work than draining and refilling, especially with the drain plug's notoriety for being fragile.

Took me 1.5 hours from walking out to the garage to finishing up the cleanup and checking for leaks. A big improvement over the 3 hours it took the first time.

This is a pretty straightfoward job, it's just awfully tight back there. I found that getting the thermostat housing off was best done with 10mm and 13mm combo wrenches, except for the interior bolt which had to come off with a 13mm socket on an extension. This one is a PITA but it will come off.

In addition to the normal combo wrenches and wratches, tools recommended include a 19mm stubby combo wrench (wratcheting if possible) and a nice pair of work gloves. The 19mm stubby is for removing and installing the temperature sensor. I got a GearWrench one for $12, makes this otherwise tricky part a breeze. Wratcheting 10mm and 13mm combos would also be nice for the thermostat housing, but not necessary.

This is a tight job and your hands will take a beating if not protected. I've got a pair of Klein Tools brand carpentry gloves with open thumb, pointer, and middle fingertips.

Another tip: the coolant hose from the thermostat to the radiator is stuck on pretty tight. I used a pair of pliers to get the hose clamp off, then the tip of a small flathead screwdriver to work the end of the hose loose. It needed a little help but came off without too much trouble.

The car took almost an entire jug of the Prestone 50/50 mix-with-anything coolant top off.

jeff




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