Catera 2000-2001

Removal & Installation

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CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the coolant.
  4.  
  5. Remove the intake plenum.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Remove the power steering reservoir bracket bolt and the power steering reservoir bracket.
  10.  
  11. Reposition the power steering reservoir.
  12.  
  13. Remove the radiator inlet hose clamp from the thermostat outlet pipe.

    Click image to see an enlarged view

    Fig. Radiator inlet to thermostat outlet hose

  14.  
  15. Remove the radiator inlet hose (1) from the thermostat outlet pipe.

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    Fig. Thermostat outlet bolt

  16.  
  17. Remove the thermostat outlet pipe bolt (1).
  18.  
  19. Remove the thermostat outlet pipe (2). Discard the O-rings.

    Click image to see an enlarged view

    Fig. Thermostat outlet pipe

  20.  
  21. Remove and discard the O-ring seals from the thermostat outlet pipe.

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    Fig. Thermostat housing bolts

  22.  
  23. Remove the thermostat housing bolts (1).
  24.  
  25. Remove the thermostat housing (2).
  26.  
  27. Remove and discard the seal ring.
  28.  

To install:

  1. Install a new seal ring.
  2.  
  3. Install the thermostat with the thermostat outlet housing (2) to the engine.

    Click image to see an enlarged view

    Fig. Thermostat outlet housing

  4.  
  5. Apply sealant to the thermostat housing bolt threads.
  6.  
  7. Install the thermostat outlet housing bolts (1). Tighten to 15 ft. lbs. (20 Nm).
  8.  
  9. Lubricate two new O-rings with coolant.

    Click image to see an enlarged view

    Fig. Thermostat outlet pipe

  10.  
  11. Install the new O-rings in the thermostat outlet pipe.
  12.  
  13. Install the thermostat outlet pipe (2).
  14.  
  15. Install the thermostat outlet pipe bolt (1). Tighten to 15 ft. lbs (20 Nm).

    Click image to see an enlarged view

    Fig. Thermostat pipe bolt location

  16.  
  17. Install the radiator inlet hose to the thermostat outlet pipe.
  18.  
  19. Install the radiator inlet hose clamp to the thermostat outlet pipe.
  20.  
  21. Install the power steering reservoir and the power steering reservoir bracket.
  22.  
  23. Install the power steering reservoir bracket bolt and tighten to 62 inch lbs. (7 Nm).
  24.  
  25. Install the intake manifold.
  26.  
  27. Install the intake plenum.
  28.  
  29. Fill the cooling system.
  30.  

 
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