Malibu 2001-2005

Removal & Installation

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2.2L Engine



  1. Drain the cooling system.

    Click image to see an enlarged view

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

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

    Click image to see an enlarged view

    Fig. Remove the thermostat and retaining sleeve

  6.  
  7. Remove the thermostat and retaining sleeve, noting 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-rings with coolant only.

  2.  
  3. Install the thermostat housing to water pump feed pipe.
  4.  
  5. Install the thermostat housing to water pump feed pipe bolt, and tighten the bolt to 89 lb inches (10 Nm).
  6.  
  7. Fill the cooling system.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.

    Click image to see an enlarged view

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

  4.  
  5. Remove the thermostat housing to water pump feed pipe bolts.
  6.  
  7. Remove the thermostat housing to water pump feed pipe.

    Click image to see an enlarged view

    Fig. Remove the thermostat and retaining sleeve

  8.  
  9. Remove the thermostat and retaining sleeve, noting orientation for installation.
  10.  

To install:

  1. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
    NOTE
    Lubricate the O-rings with coolant only.

  2.  
  3. Install the thermostat housing to water pump feed pipe.
  4.  
  5. Install the thermostat housing to water pump feed pipe bolt, and tighten the bolt to 89 lb inches (10 Nm).
  6.  
  7. Fill the cooling system.
  8.  

3.1L Engines



  1. Remove the thermostat housing.
  2.  
  3. Remove the thermostat.
  4.  
  5. Clean the mating surfaces.

    Click image to see an enlarged view

    Fig. The removal and installation of the thermostat

  6.  

To install:

  1. Install the thermostat.
  2.  
  3. Install the thermostat housing.
  4.  
  5. Inspect the system for leaks.
  6.  

3.5L (LX9) Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the air cleaner intake duct.
  4.  
  5. Partially drain the cooling system.
  6.  
  7. Use the special tool J38185 in order to reposition the hose clamp from the water outlet housing.
  8.  
  9. Remove the radiator inlet hose from the water outlet housing.

    Click image to see an enlarged view

    Fig. Remove the water outlet housing

  10.  
  11. Remove the water outlet housing bolts.

    Click image to see an enlarged view

    Fig. Remove the water outlet housing

  12.  
  13. Remove the water outlet housing.
  14.  
  15. Remove the thermostat.
  16.  
  17. Clean and inspect the water outlet housing gasket mating surfaces.

    Click image to see an enlarged view

    Fig. The removal and installation of the thermostat

  18.  

To install:

  1. Install the thermostat.
  2.  
  3. Install the water outlet housing.
  4.  
  5. Install the water outlet housing bolts, and tighten the bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the radiator inlet hose to the water outlet housing.
  8.  
  9. Use the special tool J38185 in order to reposition and install the hose clamp to the water outlet housing.
  10.  
  11. Install the air cleaner intake duct.
  12.  
  13. Fill the cooling system.
  14.  

3.5L (LZ4) & 3.9L (LZ9) Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Reposition the radiator outlet hose clamp at the thermostat housing.
  8.  
  9. Remove the radiator outlet hose from the thermostat housing.
  10.  
  11. Remove the thermostat housing bolt and stud.
  12.  
  13. Remove the thermostat housing and gasket.
  14.  
  15. Remove the thermostat.
  16.  
  17. Clean the gasket surfaces.

    Click image to see an enlarged view

    Fig. Thermostat, housing and mounting bolts

  18.  

To install:

  1. Install a new thermostat.
  2.  
  3. Position a new gasket and the thermostat housing to the engine block.
  4.  
  5. Install the thermostat housing bolt and stud. Tighten the bolt and stud to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the radiator outlet hose to the thermostat housing.
  8.  
  9. Position the radiator outlet hose clamp at the thermostat housing.
  10.  
  11. Install the air cleaner outlet duct.
  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Inspect the system for leaks.
  16.  

3.5L Engine



  1. Remove the air cleaner intake duct.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Use the special tool J38185 in order to reposition the hose clamp from the water outlet housing.
  6.  
  7. Remove the radiator inlet hose from the water outlet housing.

    Click image to see an enlarged view

    Fig. Remove the water outlet housing

  8.  
  9. Remove the water outlet housing bolts.

    Click image to see an enlarged view

    Fig. Remove the water outlet housing

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

    Click image to see an enlarged view

    Fig. The removal and installation of the thermostat

  16.  

To install:

  1. Install the thermostat.
  2.  
  3. Install the water outlet housing.
  4.  
  5. Install the water outlet housing bolts, and tighten the bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the radiator inlet hose to the water outlet housing.
  8.  
  9. Use the special tool J38185 in order to reposition and install the hose clamp to the water outlet housing.
  10.  
  11. Install the air cleaner intake duct.
  12.  
  13. Fill the cooling system.
  14.  

 
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