Engine Coolant Thermostat Housing Replacement L61
Removal Procedure
- Remove the intake manifold cover. Refer to
Intake Manifold Cover Replacement
.
- Drain the cooling system. Refer to
Cooling System Draining and Filling
.
Important: A drain has been provided at the bottom of the water pump for engine block coolant drainage.
- Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
- Lower the vehicle.
- If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature
(ECT) sensor electrical connector (3).
- Remove the heated oxygen sensor (HO2S) electrical connector clip from the thermostat housing.
- If equipped with a manual transaxle, disconnect the ECT sensor electrical connector (3).
- Remove the ECT sensor, if necessary.
- Reposition the radiator outlet hose clamp (1) at the thermostat cover.
- Remove the radiator outlet hose from the thermostat cover.
- Remove the exhaust heat shield studs (2).
- Remove the exhaust heat shield (1).
- Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
- Disconnect the heater inlet and outlet hoses (1, 2) from the thermostat housing pipes.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
.
- Remove the thermostat housing bolts.
Important: Twist the water transfer pipe while pulling in order to remove it from the water pump.
- Remove the thermostat from the vehicle.
- Remove the water transfer pipe from the thermostat housing, if necessary.
- Remove and discard the water transfer pipe O-ring seals, if necessary.
- Remove the thermostat cover bolts and cover, if necessary.
- Remove the thermostat, if necessary.
- Remove and discard the thermostat cover O-ring seal, if necessary.
- Remove all debris and thread sealant from the ECT sensor and bolt holes if the housing is being re-used.
Installation Procedure
- Install a NEW thermostat cover O-ring seal into the recess groove.
- Install the thermostat, if necessary.
Notice: Refer to Fastener Notice in the Preface section.
- Install the thermostat cover bolts, if necessary.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Install a NEW thermostat housing to engine gasket onto the thermostat housing.
- Load the thermostat housing assembly into position.
Important: The water feed pipe seals can be lightly lubricated with coolant to aid during installation.
- Install NEW O-ring seals onto the water feed pipe.
Important: Lubricate the O-rings with coolant ONLY.
- Install the water feed pipe into the thermostat housing aligning locator tab.
- Align the water pipe to water pump.
- Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
- Position the thermostat housing against the engine.
- Install the thermostat housing bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Lower the vehicle.
- Connect the heater inlet and outlet hoses (1, 2) to the thermostat housing pipes.
- Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
- Install the exhaust heat shield (1).
- Install the exhaust heat shield studs (2).
Tighten
Tighten the studs to 22 N·m (16 lb ft).
- Install the radiator outlet hose to the thermostat cover.
- Position the radiator outlet hose clamp (1) at the thermostat cover.
- If reinstalling the old sensor, coat the threads with
sealant. Refer to
Adhesives, Fluids, Lubricants, and Sealers
.
- Install the ECT sensor, if necessary.
Tighten
Tighten the sensor to 20 N·m (15 lb ft).
- If equipped with a manual transaxle, connect the ECT sensor electrical connector (3).
- If equipped with an automatic transaxle, perform the following steps, connect the ECT sensor electrical connector (3).
- Connect the HO2S electrical connector clip to the thermostat housing.
Important: The vehicle must be level when filling the cooling system.
- Verify the drain valves at the radiator and water pump are closed.
- Lower the vehicle.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
- Install the intake manifold cover. Refer to
Intake Manifold Cover Replacement
.
Engine Coolant Thermostat Housing Replacement LE5
Removal Procedure
- Remove the intake manifold cover. Refer to
Intake Manifold Cover Replacement
.
- Drain the cooling system. Refer to
Cooling System Draining and Filling
.
Important: A drain has been provided at the bottom of the water pump for engine block coolant drainage.
- Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
- Lower the vehicle.
- For access, reposition the underhood electrical center/junction block bracket. Refer to
Underhood Electrical Center or Junction Block Bracket Replacement
.
- If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature
(ECT) sensor electrical connector (3).
- Remove the heated oxygen sensor (HO2S) electrical connector clip from the thermostat housing.
- If equipped with a manual transaxle, disconnect the ECT sensor electrical connector (3).
- Remove the ECT sensor, if necessary.
- Reposition the radiator surge tank outlet hose clamp (1) at the thermostat
cover.
- Reposition the radiator surge tank outlet hose clamp (2) at the oil cooler.
- Remove the radiator surge tank outlet hose from the thermostat cover and oil cooler.
- Reposition the radiator outlet hose clamp (1) at the thermostat housing.
- Remove the radiator outlet hose from the thermostat housing.
- Reposition the radiator outlet hose clamp (1) at the thermostat cover.
- Remove the radiator outlet hose from the thermostat cover.
- Remove the exhaust heat shield studs (2).
- Remove the exhaust heat shield (1).
- Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
- Disconnect the heater inlet (2) and outlet (1) hoses from the thermostat housing pipes.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
.
- Remove the thermostat housing bolts.
Important: Twist the water transfer pipe while pulling in order to remove it from the water pump.
- Remove the thermostat from the vehicle.
- Remove the water transfer pipe from the thermostat housing, if necessary.
- Remove and discard the water transfer pipe O-ring seals, if necessary.
- Remove the thermostat cover bolts and cover, if necessary.
- Remove the thermostat, if necessary.
- Remove and discard the thermostat cover O-ring seal, if necessary.
- Remove all debris and thread sealant from the ECT sensor and bolt holes if the housing is being re-used.
Installation Procedure
- Install a NEW thermostat cover O-ring seal into the recess groove.
- Install the thermostat, if necessary.
Notice: Refer to Fastener Notice in the Preface section.
- Install the thermostat cover bolts, if necessary.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Install a NEW thermostat housing to engine gasket onto the thermostat housing.
- Load the thermostat housing assembly into position.
Important: The water feed pipe seals can be lightly lubricated with coolant to aid during installation.
- Install NEW O-ring seals onto the water feed pipe.
Important: Lubricate the O-rings with coolant ONLY.
- Install the water feed pipe into the thermostat housing aligning locator tab.
- Align the water pipe to water pump.
- Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
- Position the thermostat housing against the engine.
- Install the thermostat housing bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Lower the vehicle.
- Connect the heater inlet (2) and outlet (1) hoses to the thermostat housing pipes.
- Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
- Install the exhaust heat shield (1).
- Install the exhaust heat shield studs (2).
Tighten
Tighten the studs to 22 N·m (16 lb ft).
- Install the radiator outlet hose to the thermostat cover.
- Reposition the radiator outlet hose clamp (1) at the thermostat cover.
- Install the radiator outlet hose to the thermostat housing.
- Position the radiator outlet hose clamp (1) at the thermostat housing.
- Install the radiator surge tank outlet hose to the thermostat cover and oil cooler.
- Position the radiator surge tank outlet hose clamp (2) at the oil cooler.
- Position the radiator surge tank outlet hose clamp (1) at the thermostat cover.
- If reinstalling the old sensor, coat the threads with
sealant. Refer to
Adhesives, Fluids, Lubricants, and Sealers
.
- Install the ECT sensor, if necessary.
Tighten
Tighten the sensor to 20 N·m (15 lb ft).
- If equipped with a manual transaxle, connect the ECT sensor electrical connector (3).
- If equipped with a automatic transaxle, perform the following steps, connect the ECT sensor electrical connector (3).
- Connect the HO2S electrical connector clip to the thermostat housing.
Important: The vehicle must be level when filling the cooling system.
- Verify the drain valves at the radiator and water pump are closed.
- Lower the vehicle.
- Position the underhood electrical center/junction block bracket. Refer to
Underhood Electrical Center or Junction Block Bracket Replacement
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.
- Install the intake manifold cover. Refer to
Intake Manifold Cover Replacement
.
Engine Coolant Thermostat Housing Replacement LNF