Answer

 

REMOVAL & INSTALLATION

See Figures 1, 2, 3, 4, 5 and 6

1. Make sure the engine is cold, and position a suitable clean drainpan under the radiator and engine drains. Open the radiator drain and remove the engine drain plug located at the front right of the engine, draining the coolant into the container.

When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old. 

2. Disconnect the lower radiator hose from the thermostat housing.

3. Remove the 2 bolts from the water inlet housing, then remove the housing and thermostat assembly. Remove and discard the O-ring from the mating surface.

4. Remove the thermostat from the housing using the tool provided with the replacement thermostat element.

To install:

The thermostat will not function correctly if it has come in contact with oil. If oil is found in the cooling system at any time, both the thermostat cartridge must be replaced and the cooling system must be flushed.

5. Install the replacement thermostat using the tool provided, being careful not to damage or scratch the aluminum surface. Make sure the element' retaining tangs are properly seated in the 2 legs and the element piston is correctly positioned in the inlet housing.

6. Install a new O-ring and position the housing to the engine. Tighten the retaining bolts to 22 ft. lbs. (30 Nm).

7. Close the radiator drain plug and install the cylinder block drain plug. Tighten the block plug to 26 ft. lbs. (35 Nm).

8. Install the hose to the inlet housing.

9. Connect the negative battery cable and properly fill the engine cooling system.

10. Run the engine and check for leaks. Make sure the cooling system is filled to the proper level.

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Fig. 1: Loosen the thermostat housing bolts ...

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Fig. 2: ... then remove each bolt from the engine block

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Fig. 3: Pull the thermostat housing away from the engine block

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Fig. 4: Remove and discard the thermostat housing O-ring gasket

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Fig. 5: Use the tool provided in the replacement kit to remove the old thermostat from the housing.

Fig. 6: Unlike most thermostats which sit in the housing or engine block, the Saturn thermostat is secured to the housing by its own spring tension

 

Edited by bestservices on 11/20/2004 at 1:16 PM