Thermostat: Service and Repair

Thermostat Replacement (RPO L61)

Removal Procedure




1. Remove the intake manifold cover.
2. Drain the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5)) Draining and Filling Cooling System (GE 47716 Fill).
3. Reposition the radiator outlet hose clamp (1) at the thermostat housing.
4. Remove the radiator outlet hose from the thermostat housing.




5. Remove the thermostat cover bolts and cover, if necessary.
6. Remove the thermostat, if necessary.
7. Remove and discard the thermostat cover O-ring seal, if necessary.

Installation Procedure




1. Install a NEW thermostat cover O-ring seal into the recess groove.
2. Install the thermostat.

Notice: Refer to Fastener Notice.

3. Install the thermostat cover bolts.

Tighten the bolts to 10 N.m (89 lb in).




4. Install the radiator outlet hose to the thermostat housing.
5. Position the radiator outlet hose clamp (1) at the thermostat housing.
6. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5)) Draining and Filling Cooling System (GE 47716 Fill).
7. Install the intake manifold cover.