LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1440 (Engine Cooling) >> Repair Instructions >> Thermostat Housing Replacement >> Removal Procedure

Removal 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.
    NOTE: The thermostat will not function correctly once it is contacted by oil. If oil is found in the cooling system, it must be flushed and the thermostat's cartridge replaced.
    Fig 1: View Of Drain Valve
    GM931332Courtesy of GENERAL MOTORS CORP.
  1. Remove the coolant cap from the surge tank.
  2. Place a coolant container under the radiator drain valve at the right hand side of the radiator tank.
  3. Using a flat-bladed screwdriver, open the valve and drain the coolant.
  4. Raise the vehicle on a hoist.
    5. Fig 2: Locating Water Pump Drain Plug (L61)
    GM964352Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: A drain plug has been provided at the bottom of the water pump for engine block coolant drainage.
  5. Drain the coolant from the engine block at the water pump drain plug. After the coolant has drained, tighten the plug.
  6. Lower the vehicle.
  7. Remove the battery box. Refer to Battery Box Replacement .
    8. Fig 3: Disconnecting Lower Radiator Hose & Clamp (2.2L)
    GM931384Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the radiator hose and clamp from the thermostat pipe assembly using the J 43271 Clamp Pliers, or equivalent.
    9. Fig 4: Disconnecting Surge Tank Return Hose & Clamp From Thermostat Housing Pipe (2.2L)
    GM931368Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the return hose and clamp from the thermostat housing pipe.
  10. Remove the attachment bolt from the thermostat bracket assembly to thermostat pipe assembly near the front of the engine.
    11. Fig 5: Exhaust Heat Shield Bolts (2.2L)
    GM951386Courtesy of GENERAL MOTORS CORP.
  11. Remove the exhaust heat shield bolts.
  12. Remove the exhaust heat shield.
  13. Disconnect the electrical connector at the coolant temperature sensor.
  14. Disconnect the O2 sensor connector and clip from the bracket.
    15. Fig 6: Disconnecting Heater Inlet & Outlet Hoses From Thermostat Housing Pipes (2.2L)
    GM931420Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the coolant hoses and clamps at the thermostat housing pipes.
    16. Fig 7: Draining Coolant From Plug At Bottom Of Water Pump (2.2L)
    GM951404Courtesy of GENERAL MOTORS CORP.
  16. Remove the thermostat housing bolts to the engine.
    17. IMPORTANT: Twist the water pipe while pulling to remove it from the water pump.
  17. Remove the water pipe from the thermostat housing.
  18. Remove the thermostat housing assembly from the vehicle.
    19. Fig 8: Thermostat Housing Assembly (L61)
    GM951792Courtesy of GENERAL MOTORS CORP.
  19. Remove the water transfer pipe O-seals and discard.
  20. Remove the thermostat housing cover bolts and cover.
  21. Remove and discard the thermostat housing O-seal.
  22. Remove the thermostat cartridge and inner sleeve from the thermostat housing.
  23. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.
scientia non olet · About LEMON Manuals