GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 HHR 🢒 Engine 🢒 Engine Exhaust 🢒 Engine Coolant Thermostat Housing Replacement

Engine Coolant Thermostat Housing Replacement LNF


Object Number: 2009677 Size: MF

Callout

Component Name

Preliminary Procedures

  1. Partially drain the coolant system. Refer to Cooling System Draining and Filling.
  2. Remove the thermostat. Refer to Engine Coolant Thermostat Replacement.
  3. Disconnect the inlet and outlet heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement.
  4. Remove the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement.

    5. Note: If replacing the engine coolant thermostat housing, transfer the coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement.

  5. Disconnect the coolant temperature sensor harness connector.

1

Thermostat Housing Bolt (Qty: 3)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
10 N·m (89 lb in)

2

Thermostat Housing

3

Water Inlet Seal

Procedure

Use a new seal.

Engine Coolant Thermostat Housing Replacement L61 /LE5

Removal Procedure

    Object Number: 1631385 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 2.2L (L61) engine or Air Cleaner Assembly Replacement for the 2.4L engine.
  3. Remove the air cleaner bracket nuts.
  4. Remove the air cleaner bracket.

    5. Object Number: 1631387 Size: SH
  5. Remove the exhaust heat shield studs (2).
  6. Remove the exhaust heat shield (1).

    7. Object Number: 1212666 Size: SH

    Important: A drain has been provided at the bottom of the water pump for engine block coolant drainage.

  7. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt.
  8. Lower the vehicle.

    9. Object Number: 1625483 Size: SH
  9. If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
  10. Disconnect the heated oxygen sensor (HO2S) electrical connector clip from the thermostat housing.

    11. Object Number: 1625486 Size: SH
  11. If equipped with a manual transaxle, disconnect the ECT sensor electrical connector (1).

    12. Object Number: 1713085 Size: SH
  12. Remove the ECT sensor.

    13. Object Number: 1713958 Size: SH
  13. Reposition the radiator outlet hose clamp at the thermostat housing.
  14. Remove the radiator outlet hose from the thermostat housing.

    15. Object Number: 1625419 Size: SH
  15. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  16. Disconnect the heater inlet and outlet hoses from the thermostat housing pipes.
  17. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

    18. Object Number: 1713067 Size: SH
  18. Remove the thermostat housing bolts.

    19. Important: Twist the water transfer pipe while pulling in order to remove it from the water pump.

  19. Remove the thermostat housing from the vehicle.
  20. Remove the water transfer pipe from the thermostat housing, if necessary.
  21. Remove and discard the water transfer pipe O-ring seals, if necessary.

    22. Object Number: 1713064 Size: SH
  22. Remove the thermostat housing cover bolts and cover, if necessary.
  23. Remove the thermostat, if necessary.
  24. Remove and discard the thermostat housing O-ring seal, if necessary.
  25. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.

Installation Procedure

    Object Number: 1713064 Size: SH
  1. Install a NEW thermostat housing cover O-ring seal into the recess groove.
  2. Install the thermostat, if necessary.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the thermostat housing cover bolts, if necessary.

    4. 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. Object Number: 1713067 Size: SH

    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.

    12. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  12. Lower the vehicle.

    13. Object Number: 1625419 Size: SH
  13. Connect the heater inlet and outlet hoses to the thermostat housing pipes.
  14. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.

    15. Object Number: 1713958 Size: SH
  15. Install the radiator outlet hose to the thermostat housing.
  16. Position the radiator outlet hose clamp at the thermostat housing.

    17. Object Number: 1713085 Size: SH
  17. If reinstalling the old sensor, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  18. Install the ECT sensor.

    19. Tighten
    Tighten the sensor to 20 N·m (15 lb ft).


    Object Number: 1625486 Size: SH
  19. If equipped with a manual transaxle, connect the ECT sensor electrical connector (1).

    20. Object Number: 1625483 Size: SH
  20. If equipped with a automatic transaxle, perform the following steps, connect the ECT sensor electrical connector (1).
  21. Connect the HO2S electrical connector clip to the thermostat housing.

    22. Object Number: 1212666 Size: SH

    Important: The vehicle must be level when filling the cooling system.

  22. Verify the drain valves at the radiator and water pump are closed.
  23. Fill the cooling system. Refer to Cooling System Draining and Filling .
  24. Lower the vehicle.

    25. Object Number: 1631387 Size: SH
  25. Install the exhaust heat shield (2).
  26. Install the exhaust heat shield studs (1).

    27. Tighten
    Tighten the studs to 22 N·m (16 lb ft).


    Object Number: 1631385 Size: SH
  27. Install the air cleaner bracket.
  28. Install the air cleaner bracket nuts.

    29. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 2.2L (L61) engine or Air Cleaner Assembly Replacement for the 2.4L engine.
  30. Verify the repair and inspect for any leaks.