GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Aztek - AWD 🢒 Engine 🢒 Engine Electrical 🢒 Thermostat Bypass Pipes Replacement

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure
  1. Drain the cooling system. Refer to Cooling System Draining and Filling .
  2. Remove the spark plug wire harness from the thermostat bypass pipe.
  3. Remove the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.4L.
  4. Remove the upper radiator hose from the thermostat housing.
  5. Disconnect the left engine mount strut from the engine.
  6. Remove the Secondary Air Injection (A.I.R.) crossover pipe. Refer to Secondary Air Injection Crossover Pipe/Hose Replacement in Engine Controls - 3.4L.
  7. Remove the heater hose from the bypass pipe.

    8. Object Number: 54419 Size: SH
  8. Remove the thermostat bypass pipe to throttle body nut.

    9. Object Number: 315719 Size: SH
  9. Use the J 38185 in order to remove the thermostat bypass pipe hose clamps (1,5).
  10. Remove the thermostat bypass pipe to cylinder head nut (3).
  11. Remove the thermostat bypass pipe bolt (4).

    12. Object Number: 187083 Size: SH
  12. Remove the thermostat bypass pipe hose.
  13. Remove the thermostat bypass pipe.

Installation Procedure
  1. Apply engine coolant to the bypass pipe seal in order to ease installation.
  2. Install the thermostat bypass pipe.

    3. Object Number: 187083 Size: SH
  3. Install the thermostat bypass pipe hose.

    4. Object Number: 315719 Size: SH
  4. Install the thermostat bypass pipe hose clamp (5).
  5. Install the thermostat bypass pipe bolt (4).

    6. Tighten
    Tighten the thermostat bypass pipe bolt to 11 N·m (98 lb in).

  6. Install the thermostat bypass pipe to cylinder head nut (3).

    7. Tighten
    Tighten the thermostat bypass pipe nut to 25 N·m (18 lb ft).

  7. Install the thermostat bypass pipe to throttle body hose clamps (1).

    8. Object Number: 54419 Size: SH
  8. Install the thermostat bypass pipe to throttle body nut.

    9. Tighten
    Tighten the thermostat bypass pipe nut to 25 N·m (18 lb ft).

  9. Install the heater hose to the bypass pipe.
  10. Install the A.I.R. crossover pipe. Refer to Secondary Air Injection Crossover Pipe/Hose Replacement in Engine Controls - 3.4L.
  11. Install the left engine mount strut from the engine.
  12. Install the upper radiator hose to the engine.
  13. Install the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.4L.
  14. Install the spark plug wire harness to the thermostat bypass pipe.
  15. Fill the cooling system. Refer to Cooling System Draining and Filling .