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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 LE5) >> Removal Procedure

Removal 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: Opening Water Pump Drain Plug (2.2L)
    GM1212666Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Drain 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) .
    3. IMPORTANT: A drain has been provided at the bottom of the water pump for engine block coolant drainage.
  3. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
  4. Lower the vehicle.
  5. For access, reposition the underhood electrical center/junction block bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement .
    6. Fig 2: Identifying Engine Harness Electrical Connectors - Top Of Engine
    GM1647986Courtesy of GENERAL MOTORS CORP.
  6. If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature (ECT) sensor electrical connector (3).
  7. Remove the heated oxygen sensor (HO2S) electrical connector clip from the thermostat housing.
    8. Fig 3: Identifying Engine Harness Electrical Connectors
    GM1648166Courtesy of GENERAL MOTORS CORP.
  8. If equipped with a manual transaxle, disconnect the ECT sensor electrical connector (3).
    9. Fig 4: View Of ECT Sensor
    GM773501Courtesy of GENERAL MOTORS CORP.
  9. Remove the ECT sensor, if necessary.
    10. Fig 5: View Of Radiator Surge Tank Outlet Hose From Thermostat Cover And Oil Cooler
    GM1656116Courtesy of GENERAL MOTORS CORP.
  10. Reposition the radiator surge tank outlet hose clamp (1) at the thermostat cover.
  11. Reposition the radiator surge tank outlet hose clamp (2) at the oil cooler.
  12. Remove the radiator surge tank outlet hose from the thermostat cover and oil cooler.
    13. Fig 6: View Of Radiator Outlet Hose From Thermostat Housing
    GM1656115Courtesy of GENERAL MOTORS CORP.
  13. Reposition the radiator outlet hose clamp (1) at the thermostat housing.
  14. Remove the radiator outlet hose from the thermostat housing.
    15. Fig 7: Identifying Radiator Outlet Hose Clamp
    GM1649362Courtesy of GENERAL MOTORS CORP.
  15. Reposition the radiator outlet hose clamp (1) at the thermostat cover.
  16. Remove the radiator outlet hose from the thermostat cover.
    17. Fig 8: Identifying Exhaust Manifold Heat Shield
    GM1631387Courtesy of GENERAL MOTORS CORP.
  17. Remove the exhaust heat shield studs.
  18. Remove the exhaust heat shield.
    19. Fig 9: Disconnecting Heater Inlet And Outlet Hoses From Thermostat Housing Pipes
    GM1656127Courtesy of GENERAL MOTORS CORP.
  19. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  20. Disconnect the heater inlet (2) and outlet (1) hoses from the thermostat housing pipes.
  21. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    22. Fig 10: Identifying Thermostat Housing Bolts
    GM1713067Courtesy of GENERAL MOTORS CORP.
  22. Remove the thermostat housing bolts.
    23. IMPORTANT: Twist the water transfer pipe while pulling in order to remove it from the water pump.
  23. Remove the thermostat from the vehicle.
  24. Remove the water transfer pipe from the thermostat housing, if necessary.
  25. Remove and discard the water transfer pipe O-ring seals, if necessary.
    26. Fig 11: Identifying Thermostat Housing Cover Bolts & Cover
    GM1713064Courtesy of GENERAL MOTORS CORP.
  26. Remove the thermostat cover bolts and cover, if necessary.
  27. Remove the thermostat, if necessary.
  28. Remove and discard the thermostat cover O-ring seal, if necessary.
  29. Remove all debris and thread sealant from the ECT sensor and bolt holes if the housing is being re-used.
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