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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) >> 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. 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) .
    2. IMPORTANT: A drain has been provided at the bottom of the water pump for engine block coolant drainage.
  2. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
  3. Lower the vehicle.
  4. Remove the front heated oxygen sensor (HO2S) electrical connector clip from the thermostat housing.
    5. Fig 2: Identifying PCV Vent Tube
    GM1649566Courtesy of GENERAL MOTORS CORP.
  5. Remove the positive crankcase ventilation (PCV) vent tube/hose bolt (4) and nuts (2, 5).
  6. Reposition the PCV vent tube/hose clamps (1, 3).
  7. Remove the PCV vent tube/hose from the air cleaner outlet duct, and the camshaft cover.
  8. Remove the PCV vent tube/hose from the engine.
    9. Fig 3: Identifying Radiator Outlet Hose
    GM1649568Courtesy of GENERAL MOTORS CORP.
  9. Reposition the radiator outlet hose clamp at the thermostat cover.
  10. Remove the radiator outlet hose from the thermostat cover.
    11. Fig 4: Identifying Oil Cooler Inlet & Outlet Hoses
    GM1649567Courtesy of GENERAL MOTORS CORP.
  11. Reposition the radiator surge tank outlet hose clamp (1) at the thermostat cover.
  12. Remove the radiator surge tank outlet hose from the thermostat cover.
  13. Reposition the oil cooler inlet and outlet hose (2, 3) clamps at the thermostat cover.
  14. Remove the oil cooler inlet and outlet hoses from the thermostat cover.
    15. Fig 5: Identifying Exhaust Manifold Heat Shield
    GM1631387Courtesy of GENERAL MOTORS CORP.
  15. Remove the exhaust heat shield studs (2).
  16. Remove the exhaust heat shield (1).
    17. Fig 6: Identifying Heater Inlet & Outlet Hoses
    GM1649565Courtesy of GENERAL MOTORS CORP.
  17. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  18. Disconnect the heater inlet (1) and outlet (2) hoses from the thermostat housing pipes.
  19. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    20. Fig 7: View Of Thermostat Housing Assembly
    GM1381548Courtesy of GENERAL MOTORS CORP.
  20. Remove the thermostat housing bolts.
    21. IMPORTANT: Twist the water transfer pipe while pulling in order to remove it from the water pump.
  21. Remove the thermostat housing from the vehicle.
  22. Remove the water transfer pipe from the thermostat housing, if necessary.
  23. Remove and discard the water transfer pipe O-ring seals, if necessary.
  24. Remove the thermostat cover bolts and cover, if necessary.
  25. Remove the thermostat, if necessary.
  26. Remove and discard the thermostat cover O-ring seal, if necessary.
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