Thermostat: Service and Repair

Thermostat Replacement (RPO LE5)

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 cover.
4. Remove the radiator outlet hose from the thermostat cover.




5. Reposition the radiator surge tank outlet hose clamp (1) at the thermostat cover.
6. Remove the radiator surge tank outlet hose from the thermostat cover.




7. Reposition the radiator outlet hose clamp (1) at the thermostat cover.
8. Remove the radiator outlet hose from the thermostat cover.




9. Remove the thermostat cover bolts and cover.
10. Remove the thermostat.
11. Remove and discard the thermostat cover O-ring seal.

Installation Procedure




1. Install a NEW thermostat cover O-ring seal.
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 cover.
5. Reposition the radiator outlet hose clamp (1) at the thermostat cover. Proceed to step 11.




6. Install the radiator surge tank outlet hose to the thermostat cover.
7. Position the radiator surge tank outlet hose clamp (1) at the thermostat cover.




8. Install the radiator outlet hose to the thermostat cover.
9. Position the radiator outlet hose clamp (1) at the thermostat cover.
10. 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).
11. Install the intake manifold cover.