[my99cavy]

2.2L Engine


Fig. 1: The thermostat is located in the lower radiator hose on the 2.2L engine


Fig. 2: Remove the two retaining bolts for on the housing


Fig. 3: Separate the housing halves to access the thermostat


Fig. 4: Pull the thermostat out to remove it from the housing


Fig. 5: The thermostat has an O-ring which goes around the center


Fig. 6: Thoroughly clean the mating surfaces of the thermostat housing

1. Disconnect the negative battery cable.
2. Properly drain and recover the coolant until the level is below the thermostat.
3. Unfasten the coolant outlet-to-inlet manifold attaching bolt and nut, then remove the outlet.
4. Remove the thermostat. Clean the inlet manifold and outlet mating surfaces.

To install:

1. Install a new O-ring onto the thermostat
2. Place the thermostat in the inlet manifold.
3. Attach the coolant outlet to the inlet manifold, using the bolt and nut. Tighten to 89 inch lbs. (10 Nm).
4. Refill the engine cooling system.
5. Connect the negative battery cable, then start the engine and check for coolant leaks.

2.3L and 2.4L Engines

1. Disconnect the negative battery cable.
2. Properly drain and recover the coolant to a level below the thermostat.
3. Unfasten the cover-to-outlet pipe bolt, which is accessible through the exhaust manifold runners.
4. Raise and safely support the vehicle.
5. Disconnect the radiator and heater hoses from the outlet pipe.
6. Unfasten the outlet pipe-to-oil pan bolt and the cover-to-outlet pipe bolts.
7. Remove the thermostat, then clean the old gasket material from the mating surfaces.

Fig. 7: Thermostat removal and installation-2.3L and 2.4L engines

To install:

1. Position the thermostat in ite correct location, then install the cover-to-outlet pipe bolt. Tighten the bolt to 10 ft. lbs. (14 Nm).
2. Install the outlet pipe-to-oil pan bolt. Tighten the pipe-to-oil pan bolt to 19 ft. lbs. (26 Nm) and the pipe-to-transaxle bolt to 40 ft. lbs. (54 Nm).
3. Connect the radiator and heater hoses to the outlet pipe.
4. Carefully lower the vehicle.
5. Install the cover-to-outlet pipe bolt through the exhaust manifold runner.
6. Properly fill the cooling system, then connect the negative battery cable.