Thermostat Housing: Service and Repair

Engine Coolant Thermostat Housing Replacement (LAT - 4 Cyl, 2.4L, MFI, Alum, DOHC, BAS (Hybrid))

Removal Procedure





1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair).

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 battery tray. Refer to Battery Tray Replacement (LAT) ()Battery Tray Replacement (LZ4/LY7) ().




5. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
6. Remove the heated oxygen sensor (HO2S) electrical connector rosebud clip from the thermostat housing.




7. Reposition the radiator outlet hose clamp at the thermostat cover.
8. Remove the radiator outlet hose from the thermostat cover.




9. Remove the exhaust heat shield bolts (1).
10. Remove the exhaust heat shield.




11. Remove the auxiliary heater water pump hose clip (1) from the heater outlet hose.
12. Reposition the auxiliary heater water pump hose clamp at the thermostat housing.
13. Remove the auxiliary heater water pump hose (2) from the thermostat housing.
14. Reposition the heater inlet hose clamp at the thermostat housing.
15. Remove the heater inlet hose (3) from the thermostat housing.
16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service Intervals).




17. Remove the ECT sensor, if necessary.




18. Remove the thermostat housing bolts.

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


19. Remove the thermostat 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. Remove the thermostat cover bolts and cover, if necessary.
23. Remove the thermostat, if necessary.
24. Remove and discard the thermostat cover O-ring seal, if necessary.
25. Remove all debris and thread sealant from the engine coolant temperature (ECT) sensor and bolt holes if the housing is being re-used.



Installation Procedure





1. Install a NEW thermostat cover O-ring seal into the recess groove.
2. Install the thermostat, if necessary.

Notice: Refer to Fastener Notice (Fastener Notice).

3. Install the thermostat cover bolts, if necessary.

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.





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.

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





12. If reinstalling the old sensor, coat the threads with sealant. Refer to Sealers, Adhesives, and Lubricants (Specifications).
13. Install the ECT sensor, if necessary.

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

14. Lower the vehicle.




15. Install the heater inlet hose (3) to the thermostat housing.
16. Position the heater inlet hose clamp at the thermostat housing.
17. Install the auxiliary heater water pump hose (2) to the thermostat housing.
18. Position the auxiliary heater water pump hose clamp at the thermostat housing.
19. Install the auxiliary heater water pump hose clip (1) to the heater outlet hose.




20. Install the exhaust heat shield.
21. Install the exhaust heat shield bolts.

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





22. Install the radiator outlet hose to the thermostat cover.
23. Position the radiator outlet hose clamp at the thermostat cover.




24. Connect the engine wiring harness electrical connector (1) to the ECT sensor.
25. Install the HO2S electrical connector rosebud clip to the thermostat housing.
26. Install the battery tray. Refer to Battery Tray Replacement (LAT) ()Battery Tray Replacement (LZ4/LY7) ().




27. Verify the drain valves at the radiator and water pump are closed.
28. Lower the vehicle.
29. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair).