GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Engine 🢒 Engine Cooling 🢒 Engine Coolant Thermostat Housing Replacement

Special Tools

    • MK-6340 Locking Tool
    • MK-6628 Locking Tool

Removal Procedure
  1. Remove the camshaft sensor of exhaust camshaft.
    2. • Disconnect the wiring harness connector.
    • Remove the bolt.
  2. Remove the camshaft sensor of intake camshaft.
    3. • Disconnect the wiring harness connector.
    • Remove the bolt.
  3. Remove the camshaft adjustment valve, exhaust camshaft.
    4. • Disconnect the wiring harness connector.
    • Disconnect the wiring harness from the cylinder head.
    • Remove the bolt.
  4. Remove the camshaft adjustment valve, intake camshaft.
    5. • Disconnect the wiring harness connector.
    • Remove the bolt.
  5. Remove the closure bolt, exhaust camshaft adjuster.
  6. Remove the intake camshaft closure bolt.
  7. Install the MK-6340 .

    8. Note: Two mechanics required.

  8. Slacken the exhaust camshaft adjuster.

    9. Counterhold at the camshaft hexagon.

  9. Detach the exhaust camshaft adjuster.

    10. Remove the bolt.

    Note: Two mechanics required.

  10. Slacken the intake camshaft adjuster.

    11. Counterhold at the camshaft hexagon.

  11. Detach the intake camshaft adjuster.

    12. Remove the bolt.

  12. Remove the rear toothed belt cover.
    13. • Unclip the wiring trough cover.
    • Remove the 4 bolts.
  13. Remove the thermostat housing.

    14. Remove the 4 bolts.

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.

  1. Attach the thermostat housing.

    2. Use a new gasket.

    Tighten
    Tighten the 4 bolts to 8 N·m (70 lb in).

  2. Clean the 4 thread, rear toothed belt cover.
  3. Install the rear toothed belt cover.
    4. • Coat the 4 bolts with locking compound (red).

    Tighten
    Tighten the 4 new bolts to 6 N·m (53 lb in).

    • Clip in the wiring trough cover.

    Note: Do not tighten the bolt.

  4. Attach the intake camshaft adjuster.

    5. Install the bolt.

    Note: Do not tighten the bolt.

  5. Attach the exhaust camshaft adjuster.

    6. Install the bolt.

    Note: Note markings on the camshaft sprockets.

  6. Insert MK-6340 .
  7. Insert MK-6628 into camshafts.

    8. Align camshafts using hexagon until MK-6628 can be inserted in both camshafts.

    Note: Two mechanics required.

  8. Tighten the exhaust camshaft adjuster.

    9. Counterhold at the camshaft hexagon.

    Tighten
    Tighten the exhaust camshaft adjuster to 65 N·m (48 lb ft) plus 120 degrees plus 15 degrees.

    Note: Two mechanics required.

  9. Tighten the intake camshaft adjuster.

    10. Counterhold at the camshaft hexagon.

    Tighten
    Tighten the intake camshaft adjuster to 65 N·m (48 lb ft) plus 120 degrees plus 15 degrees.

  10. Tighten the exhaust camshaft adjuster closure bolt.

    11. Replace the seal ring.

    Tighten
    Tighten the bolt to 30 N·m (22 lb ft).

  11. Tighten the closure bolt, intake camshaft adjuster.

    12. Replace the seal ring.

    Tighten
    Tighten the bolt to 30 N·m (22 lb ft).

  12. Install the camshaft adjustment valve, exhaust camshaft.
    13. • Tighten the bolt.
    • Clip the wiring harness to the cylinder head.
    • Connect the wiring harness plug.
  13. Install the camshaft adjustment valve, intake camshaft.
    14. • Tighten the bolt.
    • Connect the wiring harness plug.
  14. Install the camshaft sensor of exhaust camshaft.
    15. • Tighten the bolt.
    • Connect the wiring harness plug.
  15. Install the camshaft sensor, intake camshaft.
    16. • Tighten the bolt.
    • Connect the wiring harness plug.