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Home >> Saturn >> 2003 >> Ion 1 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 380 (Engine Cooling System) >> Repair Instructions >> Thermostat Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion Red Line, 2004 Saturn Ion 3, 2004 Saturn Ion 2, and 2004 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the thermostat and retaining sleeve with the dimple placed into the housing slot.
    2. Fig 1: View Of Thermostat & Retaining Sleeve
    GM789974Courtesy of GENERAL MOTORS CORP.
    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.
    3. Fig 2: Identifying Thermostat Housing
    GM789956Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the bolt that secures the water pump feed pipe.

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

    4. Fig 3: View Of Water Pump Feed Pipe
    GM789955Courtesy of GENERAL MOTORS CORP.
  4. Fill the cooling system. Refer to Draining and Filling Cooling System (2.2L (L61))  or Draining and Filling Cooling System (2.0L (LSJ)) .
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