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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 LSJ) >> 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: Lubricating Feed Tube O-Ring With Anti-Freeze
    GM1381565Courtesy 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. 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 2: Identifying Heater Inlet & Outlet Hoses
    GM1649565Courtesy of GENERAL MOTORS CORP.
  13. Connect the heater inlet (1) and outlet (2) hoses to the thermostat housing pipes.
  14. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
    15. Fig 3: 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 4: Identifying Oil Cooler Inlet & Outlet Hoses
    GM1649567Courtesy of GENERAL MOTORS CORP.
  17. Install the oil cooler inlet and outlet hoses to the thermostat cover.
  18. Position the oil cooler inlet and outlet hose (2, 3) clamps at the thermostat cover.
  19. Install the radiator surge tank outlet hose to the thermostat cover.
  20. Position the radiator surge tank outlet hose clamp (1) at the thermostat cover.
    21. Fig 5: Identifying Radiator Outlet Hose
    GM1649568Courtesy of GENERAL MOTORS CORP.
  21. Install the radiator outlet hose to the thermostat cover.
  22. Position the radiator outlet hose clamp at the thermostat cover.
    23. Fig 6: Identifying PCV Vent Tube
    GM1649566Courtesy of GENERAL MOTORS CORP.
  23. Install the PCV vent tube/hose to the engine.
  24. Install the PCV vent tube/hose to the air cleaner outlet duct, and the camshaft cover.
  25. Position the PCV vent tube/hose clamps (1, 3).
  26. Install the PCV vent tube/hose bolt (4) and nuts (2, 5).

    Tighten:  Tighten the bolt/nuts to 10 N.m (89 lb in).

  27. Connect the front HO2S electrical connector clip to the thermostat housing.
    28. Fig 7: Opening Water Pump Drain Plug (2.2L)
    GM1212666Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The vehicle must be level when filling the cooling system.
  28. Verify the drain valves at the radiator and water pump are closed.
  29. 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) .
  30. Lower the vehicle.
  31. Verify the repair and inspect for any leaks.
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