Installation Procedure

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Thermostat

Courtesy of GENERAL MOTORS CORP.

Install the thermostat cartridge into the thermostat housing while aligning the cartridge tangs up with the thermostat housing bolt holes. This will assure the inner sleeve can be completely installed.

Fig 2: Inserting Inner Sleeve Notch Into Thermostat Housing (2.2L)

Courtesy of GENERAL MOTORS CORP.

Align and insert the inner sleeve notch into the thermostat housing. If the inner sleeve notch is not properly positioned, the sleeve will not completely seat into the housing.

Fig 3: Installing New Thermostat Housing Cover Seal Into Recess Groove (2.2L)

Courtesy of GENERAL MOTORS CORP.

Install a new thermostat housing cover seal into the recess groove.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

Install the thermostat housing cover bolts.
Tighten: Tighten the Thermostat housing cover-to-thermostat housing bolts to 10 N.m (89 lb in).
Install a new thermostat housing to engine seal onto the thermostat housing.
Load the thermostat housing assembly into position while the vehicle is lowered.
Raise the vehicle.

Fig 4: Applying Silicone Gel To Water Feed Pipe Seals (L61)

Courtesy of GENERAL MOTORS CORP.

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

Install new O-seals onto the water feed pipe.
Install the water feed pipe into the thermostat housing aligning locator tab.
Align the water pipe to water pump.
Seat the water feed O-seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
Lower the vehicle.

Fig 5: Draining Coolant From Plug At Bottom Of Water Pump (2.2L)

Courtesy of GENERAL MOTORS CORP.

Position the thermostat housing against the engine. Be sure that the thermostat housing pipe is properly positioned against the support bracket near the front of the engine.
Install the thermostat housing to block bolts.
Tighten: Tighten the thermostat housing-to-block bolts to 10 N.m (89 lb in).
Install the thermostat pipe bracket-to-engine bolt.
Tighten: Tighten the thermostat pipe bracket-to-cylinder head bolt to 8 N.m (71 lb in).

Fig 6: Connecting Electrical Connector To Coolant Sensor (2.2L)

Courtesy of GENERAL MOTORS CORP.

Connect the electrical connector to coolant sensor.
Connect the O2 sensor connector and re-attach the connector to the bracket.

Fig 7: Connecting Heater Inlet & Outlet Hoses To Thermostat Housing (2.2L)

Courtesy of GENERAL MOTORS CORP.

Connect the coolant hoses to the thermostat housing and reposition the clamps, upper heater hose connects to the pipe nearest the shift cable.

Fig 8: Connecting Lower Radiator Hose & Clamp (2.2L)

Courtesy of GENERAL MOTORS CORP.

Connect the lower radiator hose and clamp.
Connect the return hose to the thermostat pipe.

Fig 9: Exhaust Manifold Heat Shield (2.2L)

Courtesy of GENERAL MOTORS CORP.

Install the exhaust manifold heat shield.
Install the exhaust manifold shield bolts.
Tighten: Tighten the exhaust manifold heat shield bolts to 23 N.m (17 lb ft).

Fig 10: Battery

Courtesy of GENERAL MOTORS CORP.

Install the battery box. Refer to Battery Box Replacement .

Fig 11: View Of Drain Valve

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: The vehicle must be level when filling the cooling system.

Verify the drain valves at the radiator and water pump are closed.

Fig 12: Disconnecting Degas Hose

Courtesy of GENERAL MOTORS CORP.

Fill the engine coolant. Refer to Draining and Filling Cooling System .
Verify the repair and inspect for any leaks.