Alero, Grand Am 1999-2005

Removal & Installation

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2.2L Engine



  1. If equipped with an automatic transaxle, remove the exhaust manifold, as outlined in this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the thermostat housing to water pump feed pipe bolts.
  6.  
  7. Remove the thermostat housing to water pump feed pipe.

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    Fig. Thermostat mounting-2.2L engine

  8.  
  9. Remove the thermostat.
  10.  

To install:

  1. Install the thermostat.
  2.  
  3. Install the thermostat housing to water pump feed pipe.
  4.  
  5. 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).
  6.  
  7. If equipped with an automatic transaxle, install the exhaust manifold, as outlined in this section.
  8.  
  9. Fill the cooling system.
  10.  

3.1L Engines



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system to a level below the thermostat housing.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Disconnect the surge tank line from the thermostat housing.
  8.  
  9. Remove thermostat housing-to-intake manifold attaching bolt and nut, then remove the housing.
  10.  
  11. Remove the thermostat.
  12.  

To install:

  1. Clean all gasket surfaces completely.
  2.  
  3. Insert the thermostat in the intake manifold.
  4.  
  5. Attach the thermostat housing to the intake manifold.
  6.  
  7. Install the mounting bolt and nut. Tighten to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Connect the surge tank line to thermostat housing.
  12.  
  13. Refill the cooling system.
  14.  
  15. 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.
  16.  
  17. Install the radiator cap, making sure the arrows line up with the overflow tube.
  18.  

3.4L Engine



  1. Drain the cooling system.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove exhaust crossover pipe.
  6.  
  7. Disconnect the surge tank line fitting from the coolant outlet.
  8.  
  9. Remove the thermostat housing to intake manifold bolts.
  10.  
  11. Remove the thermostat housing outlet and thermostat
  12.  
  13. Clean the mating surfaces.
  14.  

To install:

  1. Install the thermostat and housing outlet.
  2.  
  3. Install the thermostat housing bolts. Tighten the thermostat housing bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install exhaust crossover pipe.
  6.  
  7. Connect the surge tank line fitting to the coolant outlet. Tighten the fittings to 15 ft. lbs. (21 Nm).
  8.  
  9. Install the air cleaner.
  10.  
  11. Fill the cooling system.
  12.  
  13. Inspect the system for leaks.
  14.  

 
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