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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 784 (Engine Cooling System) >> Repair Instructions >> Engine Coolant Thermostat Housing Replacement (L61) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Water Pump Drain Plug
    GM1212666Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716 Fill)  or Cooling System Draining and Filling (Static Fill LE5, L61)  or Cooling System Draining and Filling (Static Fill LNF) .
    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. Fig 2: Identifying Engine Harness Electrical Connectors - Top Of Engine
    GM1647986Courtesy of GENERAL MOTORS CORP.
  5. If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature (ECT) sensor electrical connector (3).
  6. Remove the heated oxygen sensor (HO2S) electrical connector clip from the thermostat housing.
    7. Fig 3: Identifying Engine Harness Electrical Connectors
    GM1648166Courtesy of GENERAL MOTORS CORP.
  7. If equipped with a manual transaxle, disconnect the ECT sensor electrical connector (3).
    8. Fig 4: View Of ECT Sensor
    GM773501Courtesy of GENERAL MOTORS CORP.
  8. Remove the ECT sensor, if necessary.
    9. Fig 5: Identifying Radiator Outlet Hose Clamp
    GM1649362Courtesy of GENERAL MOTORS CORP.
  9. Reposition the radiator outlet hose clamp (1) at the thermostat cover.
  10. Remove the radiator outlet hose from the thermostat cover.
    11. Fig 6: View Of Exhaust Manifold Heat Shield
    GM1631387Courtesy of GENERAL MOTORS CORP.
  11. Remove the exhaust heat shield studs (2).
  12. Remove the exhaust heat shield (1).
    13. Fig 7: Identifying Heater Inlet & Outlet Hoses
    GM1647980Courtesy of GENERAL MOTORS CORP.
  13. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  14. Disconnect the heater inlet and outlet hoses (1, 2) from the thermostat housing pipes.
  15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    16. Fig 8: Identifying Thermostat Housing Bolts
    GM1713067Courtesy of GENERAL MOTORS CORP.
  16. Remove the thermostat housing bolts.
    17. IMPORTANT: Twist the water transfer pipe while pulling in order to remove it from the water pump.
  17. Remove the thermostat from the vehicle.
  18. Remove the water transfer pipe from the thermostat housing, if necessary.
  19. Remove and discard the water transfer pipe O-ring seals, if necessary.
    20. Fig 9: Identifying Thermostat Housing Cover Bolts & Cover
    GM1713064Courtesy of GENERAL MOTORS CORP.
  20. Remove the thermostat cover bolts and cover, if necessary.
  21. Remove the thermostat, if necessary.
  22. Remove and discard the thermostat cover O-ring seal, if necessary.
  23. Remove all debris and thread sealant from the ECT sensor and bolt holes if the housing is being re-used.
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