GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 L300/LW300 🢒 Engine 🢒 Engine Cooling 🢒 Engine Coolant Thermostat Replacement

Removal Procedure
  1. Drain the coolant. Refer to Cooling System Draining and Filling .
  2. Lift and support the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical - 3.0L (L81).
  3. Disconnect the radiator hose from the coolant pipe.

    4. Object Number: 896501 Size: SH
  4. Remove the coolant pipe/engine lift bracket bolt.
  5. Rotate the oil level indicator and tube away from the pipe.

    6. Object Number: 894725 Size: SH
  6. Remove the thermostat extension pipe.
  7. Remove and discard the O-ring seals.

    8. Object Number: 896494 Size: SH
  8. Remove the thermostat with the housing.
    9. 8.1. Remove the bolts.
    8.2. Tilt the rear of the thermostat housing upward.
    8.3. Lift out the housing.
    8.4. Remove and discard the O-ring Seal.

Installation Procedure

    Important: The SUV thermostat housing is different from L-Series.


    Object Number: 896494 Size: SH
  1. Install the thermostat with housing.
    2. 1.1. Install a new O-ring seal.
    1.2. Position the thermostat with the housing.
    1.3. Apply thread sealant PST 565® to the bolt threads.

    Notice: Refer to Fastener Notice in the Preface section.

    1.4. Install the housing bolts.

    Tighten
    Tighten the thermostat housing bolts 20 N·m (15 lb ft).


    Object Number: 894721 Size: SH
  2. Lubricate the coolant pipe O-rings with coolant.
  3. Install the O-rings on the coolant pipe.

    4. Object Number: 896501 Size: SH

    Important: The correct stack up should be cylinder, head, engine lift bracket, coolant extension housing

  4. Properly position the engine lift bracket.
  5. Install the coolant pipe into the thermostat housing.
  6. Rotate the oil level tube into position.
  7. Install the coolant pipe engine lift bracket bolt.

    8. Tighten
    Tighten the coolant pipe engine bracket bolt to 20 N·m (15 lb ft).

  8. Connect the radiator hose to the coolant pipe.
  9. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical - 3.0L (L81).
  10. Fill the cooling system. Refer to Cooling System Draining and Filling .