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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 697 (Engine Cooling System) >> Repair Instructions >> Engine Coolant Thermostat Housing Replacement (RPO L61) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Pontiac G5 Pursuit, 2007 Pontiac G5, and 2007 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Thermostat Housing Cover Bolts & Cover
    GM1713064Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW thermostat cover O-ring seal into the recess groove.
  2. Install the thermostat, if necessary.
    3. NOTE: Refer to Fastener Notice .
  3. Install the thermostat cover bolts, if necessary.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  4. Install a NEW thermostat housing to engine gasket onto the thermostat housing.
  5. Load the thermostat housing assembly into position.
    6. Fig 2: Identifying Thermostat Housing Bolts
    GM1713067Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The water feed pipe seals can be lightly lubricated with coolant to aid during installation.
  6. Install NEW O-ring seals onto the water feed pipe.
    7. IMPORTANT: Lubricate the O-rings with coolant ONLY.
  7. Install the water feed pipe into the thermostat housing aligning locator tab.
  8. Align the water pipe to water pump.
  9. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  10. Position the thermostat housing against the engine.
  11. Install the thermostat housing bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  12. Lower the vehicle.
    13. Fig 3: Identifying Heater Inlet & Outlet Hoses
    GM1647980Courtesy of GENERAL MOTORS CORP.
  13. Connect the heater inlet and outlet hoses (1, 2) to the thermostat housing pipes.
  14. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
    15. Fig 4: Identifying Exhaust Manifold Heat Shield
    GM1631387Courtesy of GENERAL MOTORS CORP.
  15. Install the exhaust heat shield (1).
  16. Install the exhaust heat shield studs (2).

    Tighten:  Tighten the studs to 22 N.m (16 lb ft).

    17. Fig 5: Identifying Radiator Outlet Hose Clamp
    GM1649362Courtesy of GENERAL MOTORS CORP.
  17. Install the radiator outlet hose to the thermostat cover.
  18. Position the radiator outlet hose clamp (1) at the thermostat cover.
    19. Fig 6: View Of ECT Sensor
    GM773501Courtesy of GENERAL MOTORS CORP.
  19. If reinstalling the old sensor, coat the threads with sealant. Refer to Sealers, Adhesives, and Lubricants .
  20. Install the ECT sensor, if necessary.

    Tighten:  Tighten the sensor to 20 N.m (15 lb ft).

    21. Fig 7: Identifying Engine Harness Electrical Connectors
    GM1648166Courtesy of GENERAL MOTORS CORP.
  21. If equipped with a manual transaxle, connect the ECT sensor electrical connector (3).
    22. Fig 8: Identifying Engine Harness Electrical Connectors - Top Of Engine
    GM1647986Courtesy of GENERAL MOTORS CORP.
  22. If equipped with an automatic transaxle, perform the following steps, connect the ECT sensor electrical connector (3).
  23. Connect the HO2S electrical connector clip to the thermostat housing.
    24. Fig 9: Opening Water Pump Drain Plug (2.2L)
    GM1212666Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The vehicle must be level when filling the cooling system.
  24. Verify the drain valves at the radiator and water pump are closed.
  25. Lower the vehicle.
  26. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ))  or Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5))  or Draining and Filling Cooling System (GE 47716 Fill) .
  27. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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