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John, ASE Certified Technician
Category: Saturn
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Experience:  Master ASE technician,Master GM technician,40 years experience
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where is the thermostat on a 04 saturn ion & how to repl

Customer Question

where is the thermostat on a 04 saturn ion & how to replace it
Submitted: 4 years ago.
Category: Saturn
Expert:  John replied 4 years ago.

Hello & Welcome to JA,

 

I am sending info on the replacement of the thermostat for your vehicle.Two different engines.

 

Engine Coolant Thermostat Replacement (RPO L61)

  1. Drain the cooling system. Object Number: 789955  Size: SH
    Click here for detailed picture of above image.
  2. Remove the bolts that secure the thermostat housing to the water pump feed pipe.
    Object Number: 789956  Size: SH
    Click here for detailed picture of above image.
  3. Remove the feed pipe.
    Object Number: 789974  Size: SH
    Click here for detailed picture of above image.
  4. Remove the thermostat and retaining sleeve, noting the orientation for installation.


    Object Number: 789974  Size: SH
    Click here for detailed picture of above image.
  1. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
    Object Number: 789956  Size: SH
    Click here for detailed picture of above image.

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

  2. Install the feed pipe that connects the thermostat housing to the water pump.

     


    Object Number: 789955  Size: SH
    Click here for detailed picture of above image.
  3. Install the bolt that secures the water pump feed pipe.

    Tighten
    Tighten the bolt to 10 N·m (18 lb in).

  4. Fill the cooling system. Engine Coolant Thermostat Replacement (RPO LSJ)

  5. Object Number:(NNN) NNN-NNNN Size: SH
    Click here for detailed picture of above image.
  6. Drain the cooling system.
  7. Remove the hoses from the thermostat housing cap.
  8. Remove the thermostat housing cap and bolts.
  9. Remove the thermostat.


    Object Number:(NNN) NNN-NNNN Size: SH
    Click here for detailed picture of above image.
  1. Install the thermostat.

     

  2. Install the thermostat housing cap bolts and cap.

    Tighten
    Tighten the bolt to 10 N·m (18 lb in).

  3. Install the hoses to the thermostat housing cap.
  4. Fill the cooling system.
Customer: replied 4 years ago.
Your diagrams are nothing like what I'm looking at. My Saturn Ion is a 2004 2.2L L4 Engine. It has two hoses from the Radiator to the engine; top left and middle/bottom right. Please advise
Expert:  John replied 4 years ago.
OK this is a 2,2 at the engine.Take another looke.
Customer: replied 4 years ago.
You have a better picture ? Don't see it coming from anywhere ??
Expert:  John replied 4 years ago.

I will opt out so another expert can help you.have a good evening.

 

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