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Thermostat Inlet Housing Replacement - L61: Removal

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.
NOTE: The thermostat will not function correctly once come in contact with oil. If oil is found in the cooling system, it must be flushed and the thermostat cartridge replaced.
  1. Remove coolant cap from surge tank.
  2. Place coolant container under radiator drain valve at right hand side of radiator tank.
  3. Using a flat bladed screwdriver, open valve and drain coolant.
    Fig 1: Draining Coolant
    G01041193Courtesy of GENERAL MOTORS CORP.
  4. Raise vehicle on a hoist.

    IMPORTANT:  A drain plug has been provided at the bottom of water pump for engine block coolant drainage.

  5. Drain coolant from engine block at water pump drain plug. After coolant has drained, tighten plug.
  6. Lower vehicle.
    Fig 2: Draining Coolant From Engine Block
    G01041194Courtesy of GENERAL MOTORS CORP.
  7. Remove battery box.
    Fig 3: Removing Battery Box
    G01041195Courtesy of GENERAL MOTORS CORP.
  8. Disconnect radiator hose and clamp from thermostat pipe assembly using Clamp Pliers J43271 (or equivalent).
    Fig 4: Disconnecting Radiator Hose And Clamp
    G01041196Courtesy of GENERAL MOTORS CORP.
  9. Disconnect return hose and clamp from thermostat housing pipe.
  10. Remove attachment bolt from thermostat bracket assembly to thermostat pipe assembly near front of engine.
    Fig 5: Disconnecting Return Hose And Clamp
    G01041197Courtesy of GENERAL MOTORS CORP.
  11. Remove exhaust heat shield bolts.
  12. Remove exhaust heat shield.
  13. Disconnect electrical connector at coolant temperature sensor.
  14. Disconnect O2 sensor connector and clip from bracket.
    Fig 6: Removing Exhaust Heat Shield Bolts
    G01041198Courtesy of GENERAL MOTORS CORP.
  15. Disconnect coolant hoses and clamps at thermostat housing pipes.
    Fig 7: Disconnect Coolant Hoses And Clamps
    G01041199Courtesy of GENERAL MOTORS CORP.
  16. Remove thermostat housing bolts to engine.

    IMPORTANT:  Twist water pipe while pulling to remove it from the water pump.

  17. Remove water pipe from thermostat housing.
  18. Remove thermostat housing assembly from vehicle.
    Fig 8: Removing Thermostat Housing Assembly
    G01041200Courtesy of GENERAL MOTORS CORP.
  19. Remove water transfer pipe O-seals and discard.
  20. Remove thermostat housing cover bolts and cover.
  21. Remove and discard thermostat housing O-seal.
  22. Remove thermostat cartridge and inner sleeve from thermostat housing.
  23. Remove all debris and thread sealant engine coolant temperature sensor and bolt holes if housing is being re-used.
    Fig 9: Removing Thermostat Cartridge And Inner Sleeve
    G01041201Courtesy of GENERAL MOTORS CORP.
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