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Bob
Bob, Auto Tech
Category: Chevy
Satisfied Customers: 4087
Experience:  Plus 40 years GM, over 30 certified with Chevrolet, ASE certified Master Tech. (Expired, Retired)
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how do I change the thermostat on a 2002 chevy malibu

Customer Question

No Comment Added
Submitted: 9 years ago.
Category: Chevy
Expert:  Bob replied 9 years ago.

Hello, on your motor, it is necessary to remove the exhaust cross over pipe to access the thermostat housing. Instruction below. Thanks

Document ID# XXXXX
2002 Chevrolet Malibu

Exhaust Crossover Pipe Replacement

Removal Procedure

  1. Remove the air cleaner assembly.
  2. Remove thermostat by-pass pipe assembly.
    Object Number: 63508  Size: SH

  3. Remove the exhaust crossover pip heat shield bolts.
  4. Remove the crossover pipe heat shield.
    Object Number: 54282  Size: SH

  5. Remove the exhaust crossover pipe bolts.
  6. Remove the exhaust crossover pipe.

Installation Procedure


    Object Number: 54282  Size: SH

  1. Install the exhaust crossover pipe.

    Notice: 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.

  2. Install the exhaust crossover pipe bolts.

    Tighten
    Tighten the exhaust crossover pipe bolts to 25 N·m (18 lb ft).


    Object Number: 63508  Size: SH

  3. Install the exhaust crossover pipe heat shield.
  4. Install the exhaust crossover pipe heat shield bolts.

    Tighten
    Tighten the exhaust crossover pipe heat shield bolts to 10 N·m (89 lb in).

  5. Install thermostat by-pass pipe assembly.
  6. Install the air cleaner assembly.
  7. Inspect for exhaust leaks.

Document ID# XXXXX
2002 Chevrolet Malibu

Document ID# XXXXX
2002 Chevrolet Malibu

Engine Coolant Thermostat Housing Replacement

Removal Procedure


    Object Number: 181846  Size: SH

  1. Drain the cooling system.
  2. Remove the air cleaner.
  3. Remove exhaust crossover pipe.
  4. Disconnect the surge tank line fitting from the coolant outlet.
  5. Remove the thermostat housing to intake manifold bolts.
  6. Remove the thermostat housing outlet and thermostat.

Installation Procedure


    Object Number: 181846  Size: SH

  1. Install the thermostat and housing outlet.

    Notice: 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.

  2. Install the thermostat housing bolts.

    Tighten
    Tighten the thermostat housing bolts to 25 N·m (18 lb ft).

  3. Install exhaust crossover pipe.
  4. Connect the surge tank line fitting to the coolant outlet.

    Tighten
    Tighten the surge tank line fitting to 21 N·m (15 lb ft).

  5. Install the air cleaner.
  6. Fill the cooling system.
  7. Inspect the system for leaks.

Document ID# XXXXX
2002 Chevrolet Malibu