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Thermostat Inlet Housing Replacement - L61: Installation

WARNING: This page is about a different car, the 2002 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install thermostat cartridge into thermostat housing while aligning cartridge tangs up with thermostat housing bolt holes. This will assure the inner sleeve can be completely installed.
    Fig 1: Installing Thermostat Cartridge
    G01041202Courtesy of GENERAL MOTORS CORP.
  2. Align and insert inner sleeve notch into thermostat housing. If the inner sleeve notch is not properly positioned, the sleeve will not completely seat into the housing.
    Fig 2: Aligning And Inserting Inner Sleeve Notch
    G01041203Courtesy of GENERAL MOTORS CORP.
  3. Install a new thermostat housing cover seal into recess groove.
  4. Install thermostat housing cover bolts.

    Torque: 

    Thermostat Housing Cover-to-Thermostat Housing Bolts - L61: 10 N.m (89 in-lbs) 

  5. Install a new thermostat housing to engine seal onto thermostat housing.
  6. Load thermostat housing assembly into position while vehicle is lowered.
  7. Raise vehicle.
    Fig 3: Installing Thermostat Housing Cover Bolts
    G01041204Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  The water feed pipe seals can be lightly lubricated with silicon gel to aid during installation.

  8. Install new O-seals onto water feed pipe.
  9. Install water feed pipe into thermostat housing aligning locator tab.
  10. Align the water pipe to water pump.
  11. Seat water feed O-seal by pushing inward toward water pump. Take care not to tear or damage O-ring.
  12. Lower vehicle.
    Fig 4: Installing Water Feed Pipe
    G01041205Courtesy of GENERAL MOTORS CORP.
  13. Position thermostat housing against engine. Be sure that thermostat housing pipe is properly positioned against the support bracket near the front of engine.
  14. Install thermostat housing to block bolts.

    Torque: 

    Thermostat Housing-to-Block Bolts - L61: 10 N.m (89 in-lbs) 

  15. Install thermostat pipe bracket-to-engine bolt.

    Torque: 

    Thermostat Pipe Bracket-to-Cylinder Head Bolt - L61: 8 N.m (71 in-lbs) 

    Fig 5: Installing Thermostat Housing To Block
    G01041206Courtesy of GENERAL MOTORS CORP.
  16. Connect electrical connector to coolant sensor.
  17. Connect O2 sensor connector and re-attach connector to bracket.
    Fig 6: Connecting Electrical Connector To Coolant Sensor
    G01041207Courtesy of GENERAL MOTORS CORP.
  18. Connect coolant hoses to thermostat housing and reposition clamps (upper heater hose connects to pipe nearest shift cable).
    Fig 7: Connecting Coolant Hoses To Thermostat Housing
    G01041208Courtesy of GENERAL MOTORS CORP.
  19. Connect lower radiator hose and clamp.
  20. Connect return hose to thermostat pipe.
    Fig 8: Connecting Return Hose
    G01041209Courtesy of GENERAL MOTORS CORP.
  21. Install exhaust manifold heat shield.
  22. Install exhaust manifold heat shield bolts.

    Torque: 

    Exhaust Manifold Heat Shield Bolt - L61: 25 N.m (18 ft-lbs) 

    Fig 9: Install Exhaust Manifold Heat Shield Bolts
    G01041210Courtesy of GENERAL MOTORS CORP.
  23. Install battery box.
    Fig 10: Installing Battery Box
    G01041211Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  Vehicle must be level when filling cooling system.

  24. Verify drain valve at radiator and water pump are closed.
    Fig 11: Verifying Drain Valve At Radiator And Water Pump Are Closed
    G01041212Courtesy of GENERAL MOTORS CORP.
  25. Fill engine coolant.
  26. Verify repair and inspect for any leaks.
    Fig 12: Installing Coolant Reservoir Cap
    G01041213Courtesy of GENERAL MOTORS CORP.
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