Thermostat Housing: Service and Repair

Engine Coolant Thermostat Housing Replacement (LE5, L61) (2.4L, 2.2L)

Removal Procedure




1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) (Service and Repair)Cooling System Draining and Filling (Static Fill-LNF) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair).
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) for the 2.0L engine or Air Cleaner Assembly Replacement (Service and Repair) for the 2.2L or 2.4L engine.
3. Remove the air cleaner bracket nuts.
4. Remove the air cleaner bracket.




5. Remove the exhaust heat shield studs (2).
6. Remove the exhaust heat shield (1).





Note: 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. 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. If equipped with a manual transaxle, disconnect the ECT sensor electrical connector (1).




12. Remove the ECT sensor.




13. Reposition the radiator outlet hose clamp at the thermostat housing.
14. Remove the radiator outlet hose from the thermostat housing.




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 (Service and Repair).




18. Remove the thermostat housing bolts.

Note: 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. 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




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

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the thermostat housing cover bolts, if necessary and tighten to 10 Nm (89 lb in).
4. Install a NEW thermostat housing to engine gasket onto the thermostat housing.
5. Load the thermostat housing assembly into position.





Note: 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.

Note: 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 and tighten to 10 Nm (89 lb in).
12. Lower the vehicle.




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. Install the radiator outlet hose to the thermostat housing.
16. Position the radiator outlet hose clamp at the thermostat housing.




17. If reinstalling the old sensor, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (Specifications) or Adhesives, Fluids, Lubricants, and Sealers (Specifications).
18. Install the ECT sensor and tighten to 20 Nm (15 lb ft.




19. If equipped with a manual transaxle, connect the ECT sensor electrical connector (1).




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.





Note: 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 (Static Fill-LE5, L61) (Service and Repair)Cooling System Draining and Filling (Static Fill-LNF) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair).
24. Lower the vehicle.




25. Install the exhaust heat shield (2).
26. Install the exhaust heat shield studs (1) and tighten to 22 Nm (16 lb ft).




27. Install the air cleaner bracket.
28. Install the air cleaner bracket nuts and tighten to 10 Nm (89 lb in).
29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) for the 2.0L engine or Air Cleaner Assembly Replacement (Service and Repair) for the 2.2L or 2.4L engine.
30. Verify the repair and inspect for any leaks.