How do you install the thermostat? - Heating & Cooling

3.5L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the air cleaner intake duct.
3. Partially drain the cooling system.
4. Remove the radiator inlet hose from the thermostat housing.
5. Remove the thermostat housing bolts.
6. Remove the thermostat.
7. Clean and inspect the thermostat housing gasket mating surfaces.

To install:

1. Install the thermostat.
2. Install the thermostat housing.
3. Install the thermostat housing bolts and tighten to 18 ft. lbs. (25 Nm).
4. Install the radiator inlet hose to the thermostat housing.
5. Install the air cleaner intake duct.
6. Fill the cooling system.
7. Start the engine and check for leaks.

Thermostat Removal & Installation 2.2L Engine 2004-2005 To Remove:

1. Drain the cooling system.
   
2. Remove the thermostat housing-to-water pump feed pipe bolts.
   
3. Remove the water pump feed pipe from the thermostat housing .
4. Remove the thermostat from the housing.

To Install:

1. Install the thermostat on the housing.
2. Install the water pump feed pipe on the thermostat housing with the mounting bolts. Tighten 89 in-lb (10 Nm).
3. Fill the cooling system.

2006-2007 To Remove:

1. Drain the cooling system.
2. Disconnect the radiator outlet hose from the surge tank and thermostat housing cover. Thermostat & cover
   
3. Remove the mounting bolts and remove the thermostat housing cover.
4. Remove the thermostat from the housing. Discard the O-ring.

To Install:

1. Using a new O-ring, install the thermostat on the housing.
2. Install the thermostat housing cover with the mounting bolts. Tighten 89 in-lb (10 Nm).
3. Connect the radiator outlet hose to the surge tank and thermostat housing cover.
4. Fill the cooling system.

3.5L Engine (LZ4) W/ Variable Valve Timing & 3.9L Engine To Remove:

1. Drain the cooling system.
2. Remove the air cleaner outlet duct.
3. Disconnect the radiator outlet hose from the thermostat housing. Thermostat 3.9L
   
4. Remove the mounting bolt/stud and remove the thermostat housing.
5. Remove the thermostat from the engine.
6. Clean the sealing surfaces.

To Install:

1. Using a new gasket, install the thermostat on the engine.
2. Install the thermostat housing with the mounting bolts. Tighten 89 in-lb (10 Nm).
3. Connect the radiator outlet hose to the thermostat housing.
4. Install the air cleaner outlet duct.
5. Fill the cooling system.
6. Check the cooling system for leaks.

3.5L Engine (LX9) W/O Variable Valve Timing To Remove:

1. Drain the coolant.
2. Disconnect the radiator hose from the thermostat housing. Thermostat 3.5L
   
3. Remove the mounting bolt/stud and remove the thermostat housing.
4. Remove the housing gasket.
5. Remove the thermostat.
6. Clean the mating surfaces.

To Install:

1. Install the thermostat on the engine.
2. Install the thermostat housing and gasket with the mounting bolts. Tighten 18 ft-lb (25 Nm).
3. Connect the radiator hose to the thermostat housing.
4. Fill the cooling system.
5. Check the cooling system for leaks.

Thermostat Removal & Installation 3.4L & 3.5L Engine To Remove:

1. Drain the coolant below the level of the thermostat.
2. Remove the air cleaner and duct assembly.
3. Remove the exhaust crossover pipe.
4. Disconnect the radiator hose from the thermostat housing.
   
   
5. Remove the mounting bolts and remove the thermostat housing.
6. Remove the housing gasket.
7. Remove the thermostat.
8. Clean the mating surfaces.

To Install:

1. Install the thermostat on the engine. NOTE: Apply RTV sealer to the thermostat housing bolt threads.
   
2. Install the thermostat housing and gasket with the mounting bolts. Tighten 18 ft-lb (25 Nm).
3. Connect the radiator hose to the thermostat housing.
4. Install the exhaust crossover pipe.
5. Install the air cleaner and duct assembly.
6. Fill the cooling system.
7. Check the cooling system for leaks.

3.6L Engine To Remove:

1. Remove the air cleaner.
2. Remove the throttle body.
3. Remove the heater pipes.
4. Remove the coolant inlet pipe. Thermostat 3.6L
   
   
5. Remove the thermostat mounting bolts and remove the thermostat.
6. Clean the thermostat and heater pipe mating surfaces.

To Install:

1. Place the thermostat in the housing with a new gasket.
2. Install the thermostat and gasket on the engine with the mounting bolts. Tighten 89 in-lb (10 Nm).
3. Install the coolant inlet pipe.
4. Install the heater pipes.
5. Install the throttle body.
6. Install the air cleaner.
7. Fill the cooling system and perform a leak test.

Thermostat Removal & Installation 2.2L Engine To Remove:

1. Remove the exhaust manifold. If equipped with an automatic transmission.
2. Drain the cooling system.
3. Remove or disconnect the following:
   
   
   • Thermostat housing to water pump feed pipe bolts.
     
     
   • Thermostat housing to water pump feed pipe.
   • Thermostat.

To Install:

1. Install or connect the following:
   • Thermostat.
   • Thermostat housing to water pump feed pipe.
   • Thermostat housing to water pump feed pipe bolt.
     1. Tighten bolt to 89 in lbs (10 Nm).
   • Exhaust manifold if equipped with an automatic transmission.
2. Fill the cooling system.

2.4L Engine To Remove:
Thermostat assembly 2.4L

1. Drain the cooling system.
2. Remove the exhaust manifold heat shield.
3. Remove the coolant inlet housing mounting bolts through the exhaust manifold.
4. Raise and safely support the vehicle.
5. Remove the coolant inlet housing stud from the oil pan.
6. Remove wheel and tire assembly.
7. Remove the engine splash shield.
8. Remove the mounting bolts from the transaxle-to-engine block support. Remove the support.
9. Remove the coolant housing pipe.
10. Remove the thermostat.
11. Clean the mating surfaces.

To Install:

1. Install the thermostat.
2. Install the coolant housing pipe.
3. Install and secure the transaxle support-to-engine block mounting bolts.
4. Install the engine splash shield.
5. Install the wheel and tire assembly.
6. Install the coolant inlet housing stud to the oil pan.
   • Tighten to 19 ft lb (26 Nm).
7. Lower the vehicle.
8. Install the coolant inlet housing bolts through the exhaust manifold.
   • Tighten the coolant inlet housing bolts to 10 ft lb (14 Nm).
9. Install the exhaust manifold heat shield.
10. Fill the cooling system.
11. Inspect the system for leaks.

3.4L Engine To Remove:

1. Drain the cooling system.
2. Remove the air cleaner.
3. Remove exhaust crossover pipe.
4. Disconnect the surge tank line fitting from the coolant outlet.
5. Remove the thermostat housing to intake manifold bolts.
6. Remove the thermostat housing outlet and thermostat.

To Install:

1. Install the thermostat and housing outlet.
2. Install the thermostat housing bolts.
   • Tighten the thermostat housing bolts to 18 ft lb (25 Nm).
3. Install exhaust crossover pipe.
4. Connect the surge tank line fitting to the coolant outlet.
   • Tighten the fittings to 15 ft lb (21 Nm).
5. Install the air cleaner.
6. Fill the cooling system.
7. Inspect the system for leaks

Please see my tip at http://www.fixya.com/cars/r5929960-s_thermostat .

Specific instructions for your car are as follows. Let me know if you get stuck or have more questions.

Removal & Installation

4.2L Engine

1. Remove the necessary coolant from the radiator.
2. Remove the alternator, as outlined in the Engine Electrical Section.
3. Loosen the outlet hose clamp at the thermostat housing. Remove the outlet hose from the thermostat housing.
4. Remove the thermostat housing bolts.
5. Remove the thermostat housing from the engine block.
6. Clean all of the surfaces of the thermostat housing.
7. Clean the sealing surface of the engine block.
   

To install:

1. Install the thermostat housing to the engine block.
2. Install the thermostat housing bolts and tighten to 89 inch lbs. (10 Nm).
3. Lubricate the inner diameter of the radiator hose with engine coolant.
4. Install the outlet hose to the thermostat housing. Secure the hose with the clamp.
5. Install the alternator.
6. Fill the cooling system with specified coolant and concentration.
7. Inspect all sealing surfaces for leaks after starting the engine.

5.3L Engine
NOTE The thermostat is not serviceable separately. The water pump inlet and thermostat must be replaced as an assembly.

1. Drain the cooling system to a level below the thermostat.
2. Remove the radiator outlet hose.
3. Remove the water pump inlet bolts.
4. Remove the water pump inlet and thermostat from the water pump.

To install:

1. Install the thermostat and thermostat housing to the water pump.
2. Install the thermostat housing bolts. Tighten the bolts to 11 ft. lbs. (15 Nm).
3. Install the radiator outlet hose.
4. Properly fill the engine cooling system and check for leaks.

Thermostat Removal & Installation 3.4L & 3.5L Engine To Remove:

1. Drain the coolant below the level of the thermostat.
2. Remove the air cleaner and duct assembly.
3. Remove the exhaust crossover pipe.
4. Disconnect the radiator hose from the thermostat housing.
   
   
5. Remove the mounting bolts and remove the thermostat housing.
6. Remove the housing gasket.
7. Remove the thermostat.
8. Clean the mating surfaces.

To Install:

1. Install the thermostat on the engine. NOTE: Apply RTV sealer to the thermostat housing bolt threads.
   
2. Install the thermostat housing and gasket with the mounting bolts. Tighten 18 ft-lb (25 Nm).
3. Connect the radiator hose to the thermostat housing.
4. Install the exhaust crossover pipe.
5. Install the air cleaner and duct assembly.
6. Fill the cooling system.
7. Check the cooling system for leaks.

3.6L Engine To Remove:

1. Remove the air cleaner.
2. Remove the throttle body.
3. Remove the heater pipes.
4. Remove the coolant inlet pipe. Thermostat 3.6L
   
   
5. Remove the thermostat mounting bolts and remove the thermostat.
6. Clean the thermostat and heater pipe mating surfaces.

To Install:

1. Place the thermostat in the housing with a new gasket.
2. Install the thermostat and gasket on the engine with the mounting bolts. Tighten 89 in-lb (10 Nm).
3. Install the coolant inlet pipe.
4. Install the heater pipes.
5. Install the throttle body.
6. Install the air cleaner.
7. Fill the cooling system and perform a leak test.

Alero, Grand Am 1999-2005 Thermostat - Removal & Installation 2.2L Engine

1. If equipped with an automatic transaxle, remove the exhaust manifold, as outlined in this section.
2. Drain the cooling system.
3. Remove the thermostat housing to water pump feed pipe bolts.
4. Remove the thermostat housing to water pump feed pipe.
   
   
   Fig. Thermostat mounting-2.2L engine
   
5. Remove the thermostat.

To install:

1. Install the thermostat.
2. Install the thermostat housing to water pump feed pipe.
3. Install the thermostat housing to water pump feed pipe bolt. Tighten the thermostat housing to water pump feed pipe bolt to 89 inch lbs. (10 Nm).
4. If equipped with an automatic transaxle, install the exhaust manifold, as outlined in this section.
5. Fill the cooling system.

3.1L Engines

1. Disconnect the negative battery cable.
2. Drain the cooling system to a level below the thermostat housing.
3. Remove the air cleaner assembly.
4. Disconnect the surge tank line from the thermostat housing.
5. Remove thermostat housing-to-intake manifold attaching bolt and nut, then remove the housing.
6. Remove the thermostat.

To install:

1. Clean all gasket surfaces completely.
2. Insert the thermostat in the intake manifold.
3. Attach the thermostat housing to the intake manifold.
4. Install the mounting bolt and nut. Tighten to 18 ft. lbs. (25 Nm).
5. Install the air cleaner assembly.
6. Connect the surge tank line to thermostat housing.
7. Refill the cooling system.
8. Connect the negative battery cable, remove the radiator cap, then start the engine. Allow the engine to run with radiator cap removed, until the upper radiator hose becomes hot (thermostat open). With the engine idling, add coolant to the radiator until the level is up to the bottom of the filler neck.
9. Install the radiator cap, making sure the arrows line up with the overflow tube.

3.4L Engine

1. Drain the cooling system.
2. Remove the air cleaner.
3. Remove exhaust crossover pipe.
4. Disconnect the surge tank line fitting from the coolant outlet.
5. Remove the thermostat housing to intake manifold bolts.
6. Remove the thermostat housing outlet and thermostat
7. Clean the mating surfaces.

To install:

1. Install the thermostat and housing outlet.
2. Install the thermostat housing bolts. Tighten the thermostat housing bolts to 18 ft. lbs. (25 Nm).
3. Install exhaust crossover pipe.
4. Connect the surge tank line fitting to the coolant outlet. Tighten the fittings to 15 ft. lbs. (21 Nm).
5. Install the air cleaner.
6. Fill the cooling system.
7. Inspect the system for leaks.

Hope this help (remember comment and rated this).

300M, Concorde, Intrepid, LHS, 1998-2004
THERMOSTAT - Removal & Installation

2.7L Engine

1. Disconnect negative cable.
   CAUTION Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.
   
2. Drain cooling system.
3. Remove radiator lower hose from thermostat housing.
4. Remove nuts from heater tube flange studs.
5. Loosen starter bolt at heater tube bracket.
6. Pull heater tube out of thermostat housing and position out of the way.
7. Remove bolt and two studs.
8. Remove thermostat housing, O-ring and thermostat.
9. Remove thermostat housing bolts.
   

To install:

1. Clean gasket sealing surfaces.
   NOTE Install thermostat with the bleed valve located at the 12 o'clock position, between tabs on seal.
   
2. Install thermostat and seal into thermostat housing .
3. If removed, install two studs.
4. Install thermostat, thermostat housing and O-ring and bolt. Tighten attaching bolts to 105 inch lbs.(12 Nm).
5. Lubricate new heater return tube O-ring with coolant.
6. Position heater return tube flange over two studs. Install nuts.
7. Tighten retaining nuts to 53 inch lbs.(6 Nm).
8. Tighten starter bolt to 40 ft. lbs. (54.3 Nm).
9. Connect the lower radiator hose to the thermostat housing. Install hose clamps.
10. Refill cooling system.
11. Inspect for leaks.
12. Connect negative cable.

3.2L & 3.5L Engines

1. Disconnect negative cable.
   CAUTION Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.
   
2. Drain cooling system.
3. Raise vehicle on hoist.
4. Disconnect electrical connectors from engine oil and power steering pressure switches.
5. Disconnect radiator and heater hoses from thermostat housing.
6. Remove thermostat housing bolts.
7. Remove housing, thermostat, and gasket.
   NOTE The OEM thermostat is staked in place at the factory. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the thermostat housing using a suitable hand held grinder. It is not necessary to restake the replacement thermostat into the thermostat housing.

To install:

1. Position gasket on thermostat and housing.
2. Install thermostat housing, gasket and mounting bolts onto block. Tighten attaching bolts to 105 inch lbs. (12 Nm).
3. Install radiator hose.
4. Install bypass hose.
5. Connect electrical connectors from engine oil and power steering pressure switches.
6. Connect negative cable.
7. Fill cooling system.
8. Inspect for leaks.
9. Lower vehicle on hoist.

Hope this help (remember comment and rated this).

300M, Concorde, Intrepid, LHS, 1998-2004 - Thermostat Removal & Installation 2.7L Engine

1. Disconnect negative cable.
   CAUTION Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.
   
2. Drain cooling system.
3. Remove radiator lower hose from thermostat housing.
4. Remove nuts from heater tube flange studs.
5. Loosen starter bolt at heater tube bracket.
6. Pull heater tube out of thermostat housing and position out of the way.
7. Remove bolt and two studs.
8. Remove thermostat housing, O-ring and thermostat.
9. Remove thermostat housing bolts.

To install:

1. Clean gasket sealing surfaces.
   NOTE Install thermostat with the bleed valve located at the 12 o'clock position, between tabs on seal.
   
2. Install thermostat and seal into thermostat housing .
3. If removed, install two studs.
4. Install thermostat, thermostat housing and O-ring and bolt. Tighten attaching bolts to 105 inch lbs.(12 Nm).
5. Lubricate new heater return tube O-ring with coolant.
6. Position heater return tube flange over two studs. Install nuts.
7. Tighten retaining nuts to 53 inch lbs.(6 Nm).
8. Tighten starter bolt to 40 ft. lbs. (54.3 Nm).
9. Connect the lower radiator hose to the thermostat housing. Install hose clamps.
10. Refill cooling system.
11. Inspect for leaks.
12. Connect negative cable.

3.2L & 3.5L Engines

1. Disconnect negative cable.
   CAUTION Do not remove pressure cap with the system hot and under pressure because serious burns from coolant can occur.


2. Drain cooling system.
3. Raise vehicle on hoist.
4. Disconnect electrical connectors from engine oil and power steering pressure switches.
5. Disconnect radiator and heater hoses from thermostat housing.
6. Remove thermostat housing bolts.
7. Remove housing, thermostat, and gasket.
   NOTE The OEM thermostat is staked in place at the factory. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the thermostat housing using a suitable hand held grinder. It is not necessary to restake the replacement thermostat into the thermostat housing.
   

To install:

1. Position gasket on thermostat and housing.
2. Install thermostat housing, gasket and mounting bolts onto block. Tighten attaching bolts to 105 inch lbs. (12 Nm).
3. Install radiator hose.
4. Install bypass hose.
5. Connect electrical connectors from engine oil and power steering pressure switches.
6. Connect negative cable.
7. Fill cooling system.
8. Inspect for leaks.
9. Lower vehicle on hoist.

Hope helps with this (remember rated this) Good luck.

2001 Chevrolet Truck Venture FWD 3.4L SFI 6cyl

Removal & Installation

1. Remove the air cleaner and duct assembly.
2. Drain the coolant until the coolant level is below the thermostat.
3. Remove the crossover exhaust pipe.
4. Remove the radiator hose from the thermostat housing.
5. Remove the thermostat housing bolts and clean any sealer from the bolt threads.
   
   
   Fig. Remove the housing bolts
   
6. Remove the thermostat housing and gasket.
7. Remove the thermostat.
8. Clean the mating surfaces.

To install:




Fig. The removal and installation of the thermostat

1. Install the thermostat.
2. Install the thermostat housing and gasket.
   NOTE Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
3. Install the thermostat housing bolts and tighten them to 18 ft. lbs. (25 Nm).
4. Install the radiator hose to the thermostat housing.
5. Install the crossover exhaust pipe.
6. Install the air cleaner and duct assembly.
7. Fill the cooling system.

3.5L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the air cleaner intake duct.
3. Partially drain the cooling system.
4. Remove the radiator inlet hose from the thermostat housing.
5. Remove the thermostat housing bolts.
6. Remove the thermostat.
7. Clean and inspect the thermostat housing gasket mating surfaces.

To install:

1. Install the thermostat.
2. Install the thermostat housing.
3. Install the thermostat housing bolts and tighten to 18 ft. lbs. (25 Nm).
4. Install the radiator inlet hose to the thermostat housing.
5. Install the air cleaner intake duct.
6. Fill the cooling system.
7. Start the engine and check for leaks.

3.9L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Release the tension on the hose clamp at the thermostat housing and remove coolant hose.
4. Remove the thermostat housing mounting bolts and remove the thermostat housing.
   
   
   Fig. Remove the thermostat housing to access the thermostat-3.9L engine shown
5. Remove the thermostat.

To install:

1. Install the thermostat.
2. Install the thermostat housing and tighten the bolts to 18 ft. lbs. (25 Nm).
3. Install the coolant hose to the thermostat housing and install the hose clamp.
4. Refill the cooling system to the correct level.
5. Start the engine and check for leaks.

I hope help you whit thie (remember rated this help) Have a nice day and good luck.