ION, L-Series, S-Series 1999-2005

Removal & Installation

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2.0L Engine



  1. Drain the cooling system.
  2.  
  3. Remove the hoses from the thermostat housing cap.
  4.  
  5. Remove the thermostat housing cap and bolts.
  6.  
  7. Remove the thermostat.

    Click image to see an enlarged view

    Fig. An exploded-view of the removal and installation of the thermostat

  8.  

To install:

  1. Install the thermostat.
  2.  
  3. Install the thermostat housing cap bolts and cap, and tighten the bolt to 18 inch lbs. (10 Nm).
  4.  
  5. Install the hoses to the thermostat housing cap.
  6.  
  7. Fill the cooling system
  8.  

2.2L Engine



  1. Drain the cooling system.

    Click image to see an enlarged view

    Fig. Remove the bolts that secure the thermostat housing to the water pump feed pipe

  2.  
  3. Remove the bolts that secure the thermostat housing to the water pump feed pipe.
  4.  
  5. Remove the feed pipe.

    Click image to see an enlarged view

    Fig. Remove the thermostat and retaining sleeve, noting the orientation for installation

  6.  
  7. Remove the thermostat and retaining sleeve, noting the orientation for installation.
  8.  

To install:

  1. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
    NOTE
    Lubricate the O-ring with soapy water or coolant before installing the O-ring in the water pump.

  2.  
  3. Install the feed pipe that connects the thermostat housing to the water pump.
  4.  
  5. Install the bolt that secures the water pump feed pipe, and tighten the bolt to 18 inch lbs.(10 Nm).
  6.  
  7. Fill the cooling system.
  8.  

  1. Drain the cooling system.

    Click image to see an enlarged view

    Fig. Remove the bolts that secure the thermostat housing to the water pump feed pipe

  2.  
  3. Remove the bolts that secure the thermostat housing to the water pump feed pipe.
  4.  
  5. Remove the feed pipe.

    Click image to see an enlarged view

    Fig. Remove the thermostat and retaining sleeve, noting the orientation for installation

  6.  
  7. Remove the thermostat and retaining sleeve, noting the orientation for installation.
  8.  

To install:

  1. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
    NOTE
    Lubricate the O-ring with soapy water or coolant before installing the O-ring in the water pump.

  2.  
  3. Install the feed pipe that connects the thermostat housing to the water pump.
  4.  
  5. Install the bolt that secures the water pump feed pipe, and tighten the bolt to 18 inch lbs. (10 Nm).
  6.  
  7. Fill the cooling system.
  8.  

2.4L Engine



  1. Drain the cooling system.
  2.  
  3. Remove the intake manifold cover
  4.  
  5. Reposition the radiator outlet hose clamp (1) at the thermostat cover.
  6.  
  7. Remove the radiator outlet hose from the thermostat cover
  8.  
  9. Reposition the radiator surge tank outlet hose clamp (1) at the thermostat cover.
  10.  
  11. Remove the radiator surge tank outlet hose from the thermostat cover
  12.  
  13. Reposition the radiator outlet hose clamp (1) at the thermostat cover.
  14.  
  15. Remove the radiator outlet hose from the thermostat cover
  16.  
  17. Remove the thermostat cover bolts and cover.
  18.  
  19. Remove the thermostat.
  20.  
  21. Remove and discard the thermostat cover O-ring seal.
  22.  

To install:


NOTE
Lubricate the O-ring with soapy water or coolant before installing the O-ring in the water pump.

  1. Install a NEW thermostat cover O-ring seal.
  2.  
  3. Install the thermostat.
  4.  
  5. Install the thermostat cover bolts and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Connect all the hoses.
  8.  
  9. Fill the cooling system.
  10.  

 
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