Thermostat: Service and Repair

Thermostat Replacement (RPO LSJ)

Removal Procedure




1. 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).
2. Reposition the radiator surge tank outlet hose clamp (1) at the thermostat cover.
3. Remove the radiator surge tank outlet hose from the thermostat cover.
4. Reposition the oil cooler inlet and outlet hose clamps (1, 2) at the thermostat cover.
5. Remove the oil cooler inlet and outlet hoses from the thermostat cover.




6. Remove the thermostat cover bolts and cover.
7. Remove the thermostat.
8. Remove and discard the thermostat cover O-ring seal.

Installation Procedure




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

Notice: Refer to Fastener Notice.

3. Install the thermostat cover bolts, if necessary.

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




4. Install the oil cooler inlet and outlet hoses to the thermostat cover.
5. Position the oil cooler inlet and outlet hose clamps (1, 2) at the thermostat cover.
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. 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).