OK. I've searched and didn't find what I was looking for, so here goes.

I need to replace the thermostat on my '02 Trooper 3.5L, and it look like the entire intake manifold has to come off to do this. Is this so? If it is, it also looks like the upper plenum will have to be removed for bolt access, or are there really only 4 bolts(studs) holding the IM in place?

Next, I have the Factory Service Manual and it is a complete waste of money, I think I would have been better off with a $15 Haynes manual.

For the Tstat, it says remove the coolant intake pipe, remove the Tstat, replace the Tstat, reinstall the coolant intake pipe.

For intake manifold it has nothing other than a brief description of what an intake manifold is. Nothing for removal or reinstallation.

If somebody has them, I need torque specs for:
- intake manifold to head
- upper plenum to lower manifold
- coolant intake pipe


Thanks,
John

WOW!!!

Nobody has any insight into 3.5's???

Knowing the Helm FSMs, I am almost positive that it addresses removal of the thermostat, SOMEWHERE in the book. It is also a FSM. It usually does not list step-by-step the process for what usually requires basic mechanical skills.

Torque specs are either in the narrative or listed in a diagram somewhere at the begining of the section. It takes a bit of hunting in the picture, but they do list a torque spec for pretty much every nut and bolt in your vehicle.

Good Luck,
Michael

THE INTAKE WILL HAVE TO BE REMOVED AS A UNIT , IT DOES NOT HAVE TO BE SEPERATED,FROM THE PLUENUM CHAMBER , IF YOU DO IT THIS WAY BE SURE AND HAVE THE LARGE PLENUM GASKET HANDY ALONG WITH THE INTAKE GASKETS,

IF YOU IN FATC HAVE A FACTORY MANUAL IT WILL HAVE EVERY SPEC AND TORQUE IN IT AND IT SHOUDL BE ABOUT 2 1/2 INCHES THICK AND IS ONLY AVAILABLE FROM HELMS, THIS MANUAL WAS NEVER OFFERED AFTER 99 IN A HARD PRINT VERSION, EVERYTHING WENT OT CD AND THEY ARE ALLSO AVAILABLE FROM HELMS

INTAKE MANIFOLD TO HEAD IS 13 FT LBS ALL THE OTHER BOLTS THAT YOU WILL NEED TO REMOVE OR REPLACE WILL BE 8 MM (12 MM HEADS)AND 12-14 FT LB IS THE MAX ON ANY OF THESE

One thing I'll add...when you remove the coolant intake pipe, be careful not to nick the O-ring that seals it, or better yet have a new one on hand before you start. I say this because I've replaced my intake gaskets & T-stat before & had it all back together & running, only to find out that he coolant was leaking out around the O-ring that had gotten nicked.
I had to make up brand new cuss words to express how mad I was that I had to take the whole works apart again just to replace that #%^&*ing O-ring.

Happy wrenching. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Hey guys,
Thanks for the responses. Sorry I didn't get back sooner, but like everything else around here, this too has been pushed back.

My manual is from Helm (on cd)and I did manage to find torques specs(in drivability and emissions). Very poorly organised, IMHO.

Thanks for confirming there is no tricks of the trade, and that the IM will need to come off. Again, this is something that should be in the manual, but isn't. Oh well, I'll still get it all done.....Eventually..