Aztek, Rendezvous 2001-2005

Removal & Installation

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3.4L Engine



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

    Click image to see an enlarged view

    Fig. Remove the housing bolts

  10.  
  11. Remove the thermostat housing and gasket.
  12.  
  13. Remove the thermostat.
  14.  
  15. Clean the mating surfaces.
  16.  

To install:

Click image to see an enlarged view

Fig. The removal and installation of the thermostat

  1. Install the thermostat.
  2.  
  3. 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.

  4.  
  5. Install the thermostat housing bolts and tighten them to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the radiator hose to the thermostat housing.
  8.  
  9. Install the crossover exhaust pipe.
  10.  
  11. Install the air cleaner and duct assembly.
  12.  
  13. Fill the cooling system.
  14.  

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

    Click image to see an enlarged view

    Fig. Remove the housing bolts

  10.  
  11. Remove the thermostat housing and gasket.
  12.  
  13. Remove the thermostat.
  14.  
  15. Clean the mating surfaces.
  16.  

To install:

Click image to see an enlarged view

Fig. The removal and installation of the thermostat

  1. Install the thermostat.
  2.  
  3. 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.

  4.  
  5. Install the thermostat housing bolts and tighten them to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the radiator hose to the thermostat housing.
  8.  
  9. Install the crossover exhaust pipe.
  10.  
  11. Install the air cleaner and duct assembly.
  12.  
  13. Fill the cooling system.
  14.  

3.5L Engine



  1. Remove the thermostat housing.
  2.  
  3. Remove the thermostat.
  4.  
  5. Remove and discard the thermostat O-ring seal.
  6.  
  7. Clean and inspect the thermostat housing sealing surfaces.
  8.  

To install:

  1. Install a NEW thermostat O-ring seal.
  2.  
  3. Install the thermostat.
  4.  
  5. Install the thermostat housing.
  6.  

3.6L Engine



  1. Remove the air cleaner.
  2.  
  3. Remove the throttle body assembly.
  4.  
  5. Remove the heater pipes.
    NOTE
    Use a universal or swivel socket with a long extension in order to remove the bolts.

  6.  
  7. Remove the coolant inlet pipe.
    NOTE
    Use a universal or swivel socket with a long extension in order to remove the bolts.

  8.  
  9. Remove the thermostat bolts and the thermostat.
  10.  
  11. Clean the thermostat and heater pipe sealing surfaces.

    Click image to see an enlarged view

    Fig. Location of the thermostat-3.6L Engine

  12.  

To install:

  1. Install a NEW thermostat gasket.
  2.  
  3. Install the thermostat and gasket.
  4.  
  5. Install the thermostat bolts and tighten them to 89 inch lbs. (10 Nm).
  6.  
  7. Install the coolant inlet pipe.
  8.  
  9. Install the heater pipes.
  10.  
  11. Install the throttle body assembly.
  12.  
  13. Install the air cleaner.
  14.  
  15. Fill the cooling system.
  16.  

  1. Remove the air cleaner.
  2.  
  3. Remove the throttle body assembly.
  4.  
  5. Remove the heater pipes.
    NOTE
    Use a universal or swivel socket with a long extension in order to remove the bolts.

  6.  
  7. Remove the coolant inlet pipe.
    NOTE
    Use a universal or swivel socket with a long extension in order to remove the bolts.

  8.  
  9. Remove the thermostat bolts and the thermostat.
  10.  
  11. Clean the thermostat and heater pipe sealing surfaces.

    Click image to see an enlarged view

    Fig. Location of the thermostat-3.6L Engine

  12.  

To install:

  1. Install a NEW thermostat gasket.
  2.  
  3. Install the thermostat and gasket.
  4.  
  5. Install the thermostat bolts and tighten them to 89 inch lbs. (10 Nm).
  6.  
  7. Install the coolant inlet pipe.
  8.  
  9. Install the heater pipes.
  10.  
  11. Install the throttle body assembly.
  12.  
  13. Install the air cleaner.
  14.  
  15. Fill the cooling system.
  16.  

 
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