Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Engine Coolant Thermostat Housing Replacement (LUW)

Chevrolet Sonic Repair Manual / Powertrain / Engine / Engine Cooling / Thermostat / Engine Coolant Thermostat Housing Replacement (LUW)

Removal Procedure
  1. Remove the battery tray. Refer to Battery Tray Replacement.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling.


  4. Disconnect the engine harness connector (1) and harness fasteners (2) from the engine harness bracket, attached to the thermostat housing.

  5. Disconnect the throttle body heater inlet hose (1) and the electrical connectors  (2) from the thermostat housing.
  6. Remove the engine harness bracket nut (3) and bracket (4) from the thermostat housing.

  7. Remove the radiator inlet hose (2) from the engine coolant thermostat housing.
  8. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement.
  9. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement.


  10. Remove the engine oil cooler outlet pipe bolts (1).
  11. Remove the engine oil cooler outlet pipe (2) from the engine coolant thermostat housing.

  12. Remove the engine coolant thermostat housing mounting bolts (1) and discard the seal (2).
  13. Remove the engine coolant thermostat housing (3) from the engine.
Installation Procedure
  1. Clean the sealing surface.

  2. Install a NEW engine coolant thermostat housing seal (2).
  3. Loosely install the engine coolant thermostat housing mounting bolts (1).

  4. Caution:

    Following the proper fastener tightening sequence and torque is essential. Failure to do so may fracture the thermostat housing.

    Caution:

    Refer to Fastener Caution.

  5. Tighten the 4 engine coolant thermostat housing bolts to 8 Y (71 lb in)

    in sequence (1?E?E?E).



  6. Install NEW engine oil cooler pipe seals (4, 7).
  7. Note:

    Push the engine oil cooler pipe into the engine oil cooler.

  8. Install the engine oil cooler pipe (5).
  9. Install the 2 engine oil cooler pipe bolts (6) and tighten to 8 Y (71 lb in)

    .

  10. Install the heater inlet hose to the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement.
  11. Install the heater outlet hose to the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement.


  12. Connect the electrical connectors (2) to the engine coolant thermostat housing.
  13. Install the throttle body heater inlet hose (1) to the engine coolant thermostat housing.
  14. Install the engine coolant thermostat housing bracket (4) and nut (3) and tighten to 6 Y (53 lb in)

    .



  15. Install the radiator inlet hose (2) to the engine coolant thermostat housing.
  16. Fill the cooling system. Refer to Cooling System Draining and Filling.
  17. Install the battery tray. Refer to Battery Tray Replacement.
  18. Start the engine and check for coolant leaks.
Engine Coolant Thermostat Housing Removal
Caution: Refer to Engine Coolant Thermostat Housing Caution. Remove the engine coolant thermostat housing retainer nut (4). Remove the engine coolant thermostat housing ...

Engine Coolant Thermostat Installation
Caution: Refer to Engine Coolant Thermostat Housing Caution. Clean the engine coolant sealing surfaces. Install the engine coolant seal (1). Install the engine coolant ...

Other materials:

Detecting the Vehicle Ahead
The green vehicle ahead indicator will appear when a vehicle is detected ahead. Whenever this indicator does not appear, FCA will not respond. The indicator may disappear on curves, highway exit ramps, or hills, or due to poor visibility. The FCA system will not detect another vehicle ahead ...

TPMS Sensor Matching Process
Each TPMS sensor has a unique identification code. The identification code needs to be matched to a new tire/wheel position after rotating the tires or replacing one or more of the TPMS sensors. The TPMS sensor matching process should also be performed after replacing a spare tire with a road ...

Parking Brake Lever Replacement
Removal Procedure Remove the front floor console. Refer to Front Floor Console Replacement. Ensure that the park brake lever is in the fully released position. Disconnect the electrical connector from the park brake warning lamp switch. Using ONLY HAND TOOL ...

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