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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1726 (Engine Cooling) >> Repair Instructions >> Thermostat Replacement (L61) >> Installation Procedure

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
    GM951651Courtesy of GENERAL MOTORS CORP.
  1. 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.
    2. Fig 2: Inserting Inner Sleeve Notch Into Thermostat Housing (2.2L)
    GM951659Courtesy of GENERAL MOTORS CORP.
  2. 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.
    3. Fig 3: Applying Silicone Gel To Water Feed Pipe Seals (L61)
    GM951611Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The water feed pipe seals can be slightly lubricated with silicone gel to aid during installation.
  3. Install a new O-seal on the water pipe.
  4. Position the water pipe into the water pump assembly.
  5. Seat the water feed O-seal by pushing and twisting toward the water pump. Take care not to tear or damage the O-ring.
    6. Fig 4: Installing New Thermostat Housing Cover Seal Into Recess Groove (2.2L)
    GM951626Courtesy of GENERAL MOTORS CORP.
  6. Install the thermostat housing cover to the water pipe. The water feed pipe has a locating tab to assure proper alignment.
  7. Install a new thermostat housing cover seal into the recess groove.
  8. Position the thermostat housing cover into position.
    9. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  9. Install the thermostat housing cover bolts.

    Tighten:  Tighten the thermostat housing cover-to-thermostat housing bolts to 10 N.m (89 lb in).

    10. Fig 5: Exhaust Manifold Heat Shield (2.2L)
    GM951395Courtesy of GENERAL MOTORS CORP.
  10. Lower the vehicle.
  11. Install the exhaust manifold heat shield.
  12. Install the exhaust manifold heat shield bolts.

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

    13. Fig 6: View Of Drain Valve
    GM931332Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The vehicle must be level when filling the cooling system.
  13. Verify the drain valve at the radiator and the water pump are closed.
    14. Fig 7: Disconnecting Degas Hose
    GM931323Courtesy of GENERAL MOTORS CORP.
  14. Fill the engine coolant. Refer to Draining and Filling Cooling System .
  15. Verify the repair and inspect for any leaks.
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