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Old 09-07-2011, 10:35 PM   #2
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What I Drive: 2003 Pitch Black SVT 5 door

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Here is a quick how-to for the upgraded thermostat housing from Tousely Ford.

The kit the send is complete except for the brass plug you will need to fill the extra port on the housing.

Make sure car is stone cold before doing this.

1) Remove battery cover and disconnect battery and remove.
2) Remove battery tray.
3) Drain antifreeze from radiator. (Loosen reservoir cap to help it drain)
4) Remove coil cover & spark plug cover.
5) Loosen vent hose from valve cover.
6) Unplug connector from coil pack (I used a little flat head screw driver to loosen the clip.)
7) Unplug coolant sensor connector.
8) Unbolt capacitor next to coil pack. (7mm socket)
9) Unbolt coil pack. (I did not unplug the spark plug wires, it moves out of the way easily once unbolted.)
10) Remove coil pack bracket (3 Torx bit bolts, there is also a wiring harness attached to the bracket, loosen the vinyl clip, and you can then pull out the bracket.)
11) Remove all four hoses from thermostat housing. (I used channel locks, and the battery tray being removed made this a lot easier, I tried it once with it in place.)
12) Unbolt thermostat housing. (3 10mm bolts)
(As a side note, I had very little antifreeze drain out when I took the hoses and thermostat housing off, thank goodness, I hate a mess. I had a drip pan in place just in case.)
13) Clean head surface where thermostat housing is mounted.

I put the thermostat housing together before I mounted it on the car.

14) Install brass plug into extra port, using a little Teflon tape, and snug it up tight.
15) Put o-ring on thermostat, slide it into housing, and put on thermostat cap, tighten down the 3 supplied threaded screws. (This is a god send, next to the self taping screws on the original housing) You don't have to crank these down, they stop when they are tight enough.
16) Install supplied temp sensor. I used a little Teflon tape on this as well. 19mm wrench fits the sensor.
17) Bolt new housing onto the block. I could not find exact torque specs on this..I called Steve at Tousley, and his recommendation was to use a 1/4 drive ratchet, and tighten them until snug. (Worked like a charm.)
18) Back fill the cooling system with the hose that attaches to the back side of the thermostat housing. Fill until it starts coming out of the housing, and attach the back hose.
19) Attach remaining hoses.
20) Reverse steps 1-10. (Leaving coil cover off to check for leaks.)
21) Fill reservoir, and here is the procedure from the service manual, from Steve @ Tousley Ford.

According to the service manual,

Backfill the system through the heater hose off the back of the thermostat housing until coolant comes out of the fitting on the housing. Then replace the hose.

Then fill the degas tank and replace the cap, start the car, heater control to hot, A/C off, heater fan off.

Run the car at 2700 rpm for two cooling fan cycles to bleed out all remaining air.

In my experience you don't have to wait the full two fan cycles, as long as you have strong heat and the degas tank is full you should be good to go.

22) Check for leaks, once you are satisfied with it, replace coil cover, and take it for a test drive.

2003 Pitch Black SVTF, K&N Drop in, CFM dog bone. 155,000 miles. **SOLD**
2001 Sentra SE 2.0 w/JWT Pop Charger. RETIRED with 511,000miles.

2008 Setra SE-R Spec-V 187whp. 167 lb. ft.
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