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Old 03-19-2016, 06:29 PM   #1
destiel4ever
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Question Replacing Thermostat '92 SC, How to Remove Alternator?

I'm trying to replace the thermostat in my 92 SC, which is proving to be a major pain in the ass. Without removing the alternator there is no way I'm going to reach the lower 10mm bolt on the Thermostat. I've removed almost all bolts holding the alternator to the frame, except for the bolt at the center of the pully. I have no idea how to remove this and would love some help. Thanks.

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Old 03-19-2016, 07:21 PM   #2
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Not sure how the alternator could possibly get in the way of doing the thermostat, it's on the opposite side of the block.
Not real sure why the A/C Compressor could be in the way either, but that has 3-4 bolts to the bracket on the pulley end, then the bracket has 3-4 bolts to the block then on the back side of the compressor there's 3 bolts holding it to the back bracket (2 need to be removed, middle one just needs to be loosened).

Vid 1: https://www.youtube.com/watch?v=JEoLFrg8IUI
Vid 2: https://www.youtube.com/watch?v=dVLoeoDU5E8

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Old 03-20-2016, 04:51 AM   #3
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Question Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Now that you say that, it has to be the AC compressor. It's definitely in the way. I can't get an angle on the lower thermostat bolt without it out of the way. I need help getting it off from the side with the belt.

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Old 03-20-2016, 07:22 AM   #4
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Quote:
Originally Posted by destiel4ever View Post
Now that you say that, it has to be the AC compressor. It's definitely in the way. I can't get an angle on the lower thermostat bolt without it out of the way. I need help getting it off from the side with the belt.
It's in the way, but it IS possible. I've done it. I think I used a combination of a gear wrench and a ratchet with the appropriate swivel socket to deal with the tight quarters.

If you feel like you must move the compressor out of the way, just loosen the bracket bolts after you take off the tension off the belt and pop it off the pulley for the compressor.

Best,

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Old 03-20-2016, 08:59 AM   #5
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

A/C Compressor removal vid: https://www.youtube.com/watch?v=rVEb7kbJGGA

Says it's a 10min video, should only take about 3min if you don't have to explain every step along the way and don't get distracted by your sons friends cousin's uncle's goldfish dying... lol

I never had an S-Series with A/C that worked so one of the first things I'd always do is remove the useless baggage from under the hood, including the A/C compressor, lines and condenser that stupidly bolts to the radiator. Saves moving around 20-30lbs and makes working on things 100x easier.

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Old 03-20-2016, 09:27 AM   #6
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

My sw2 has air conditioning. I just replaced the thermostat. I dont recall the compressor in the way at all. I am not sure all the thermostat housings are the same though.

I have heard you can move the compressor quite a bit if remove its support bolts. Take the serpentine belt off first.

Can you take a picture?

Here is a piture of my cars thermostat. It is blurry but you can see the 2 bolts that need to come out.
Attached Images
File Type: jpg image.jpg (127.7 KB, 13 views)

Last edited by shortrun; 03-20-2016 at 09:35 AM..

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Old 03-20-2016, 01:29 PM   #7
destiel4ever
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Question Re: Replacing Thermostat '92 SC, How to Remove Alternator?

My first instinct was to take off the refrigerant lines so i'm just gonna go ahead and take it out completely.

So I just need to loosen the tensioner, remove the belt, remove the compressor, and then put the belt back and tighten it until it's snug?

I'm new to this.

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Old 03-20-2016, 02:27 PM   #8
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

It's an automatic tensioner, there's nothing to adjust. Just release pressure on the tensioner with a 14mm wrench (counterclock-wise direction), pull the belt off, unbolt the A/C compressor (leave the refrigerant lines attached) and set the compressor on top of the motor. Then you have plenty of room to get to the thermostat.

If you want to remove the A/C compressor for good you need to get a shorter belt; the beauty of 1st gen DOHC's like yours is when you want/need a shorter belt you just tell the parts store its a same year SL1 with or without A/C or Power Steering to get the right belt. Pretty sure they never made a "dead" pulley for removing A/C because it's cheaper & easier to just get a shorter belt.

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Old 03-20-2016, 04:15 PM   #9
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Just to be sure you understand. If you remove the compressor ac will not work again. Even after you put it back in.
Even just unbolting the compressor and moving can cause the gas - refridgerant to leak out.

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Old 03-20-2016, 09:55 PM   #10
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

If you remove the plastic splash-shield below the t-stat housing you can get another access path to that area.

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Old 03-20-2016, 10:49 PM   #11
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Quote:
Originally Posted by destiel4ever View Post
My first instinct was to take off the refrigerant lines so i'm just gonna go ahead and take it out completely.

So I just need to loosen the tensioner, remove the belt, remove the compressor, and then put the belt back and tighten it until it's snug?

I'm new to this.
Don't do that. Those lines are under significant pressure. If you un-bolt the compressor from the bracket, just leave the lines attached. There's enough slack to let you move the compressor around a few inches...which is all you need.

When you're done with the thermostat, just bolt the compressor back to it's bracket, put the belt back on, and Bob's your uncle.

Don't forget to bleed the air out of the cooling system (not the A/C). Letting the engine run for 5-10 mins with the cap off the coolant tank ought to burp most of the air out. Just make sure you keep topping it off with the appropriate mix of coolant and distilled water.

Best,

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Old 03-21-2016, 12:49 AM   #12
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

I'm also confused. I've replaced my thermostat a couple times but never disconnected anything other than the hose and the housing. You'll want a variety of socket extensions. Just like most car work you probably can't see what you're doing but just feel.

-Robert

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Old 03-21-2016, 12:42 PM   #13
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

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I'm also confused. I've replaced my thermostat a couple times but never disconnected anything other than the hose and the housing. You'll want a variety of socket extensions. Just like most car work you probably can't see what you're doing but just feel.

-Robert
Same here, done it twice without removing the AC condenser. Good 6-point socket, think I used 1/4" drive the first time. Got a set of swivel extensions later.

I remember pulling the AC condenser off for something else, exhaust manifold, maybe? unbolted it, kept hoses on, and laid it on a towel on the radiator support.

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Old 03-21-2016, 07:32 PM   #14
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

It's definitely in the way. I got a belt tensioner tool but the 13mm socket just slides around the tensioner bolt and doesn't have any grip on it.

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Old 03-21-2016, 07:33 PM   #15
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

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Originally Posted by billr View Post
If you remove the plastic splash-shield below the t-stat housing you can get another access path to that area.
There's a big metal bar underneath the t-stat housing there's no way i'm getting in from underneath.

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Old 03-21-2016, 07:53 PM   #16
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Try taking off the plastic box behind the radiator in the center. It is only one push pin, and then pull it out sideways from the air filter box. This should give you plenty of access to the tstat.

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Old 03-21-2016, 09:56 PM   #17
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

"There's a big metal bar underneath the t-stat housing there's no way i'm getting in from underneath."

Are you talking about the sway/roll bar? Yeah, it's there, but that splash-shield is a whole lot bigger. With the splash-shield off you can see and reach that lower screw. It's still not totally easy, but you don't have to do it "by feel".

Understand, I'm only experienced with the '94/'95 SL, if your '92 SC is a lot different there, then this may be bogus advice.

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Old 03-21-2016, 10:54 PM   #18
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Oh yea. Take out the resonator. It's just a single plastic rivet. Maybe that is what is in your way. The tstat is really about a 30 min job. There is no need to fiddle with the accessory belt or tensioner.

-Robert

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Old 03-22-2016, 10:32 AM   #19
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Just remembered, back in 2011, I posted a reminder to myself about the t-stat housing.

I had to do a lot of fiddling to get the right length for the sockets/extension so that I had room to maneuver the wrench handle.

For the top bolt, you want about 5" total, for the bottom bolt, around 2"

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Old 03-22-2016, 12:18 PM   #20
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Default Re: Replacing Thermostat '92 SC, How to Remove Alternator?

Quote:
Originally Posted by destiel4ever View Post
It's definitely in the way. I got a belt tensioner tool but the 13mm socket just slides around the tensioner bolt and doesn't have any grip on it.
Try using the correct 14mm socket...

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