Chevrolet Sonic Repair Manual: Engine Coolant Thermostat Replacement (LUV)

Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling.
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.



3. Remove the engine coolant temperature sensor connector (1).
4. Disconnect the radiator outlet hose connector (2) from the engine coolant thermostat and reposition. Refer to Radiator Outlet Hose Connector Replacement- Engine Side.



5. Remove the water inlet pipe mounting fasteners (1).
6. Remove the water inlet seal (3) and discard.
7. Remove the thermostat (4).

Installation Procedure

1. Clean the sealing surface.


2. Install the engine thermostat (4) into the water inlet pipe (2) with a NEW seal (3).
3. Tighten the water inlet pipe mounting fasteners (1) to 9 Y (80 lb in)

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4. Install the radiator outlet hose connector (2) to the engine coolant thermostat. Refer to Radiator Outlet Hose Connector Replacement- Engine Side.
5. Connect the engine coolant temperature sensor connector (1).
6. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
7. Fill the cooling system. Refer to Cooling System Draining and Filling.
8. After repairs, inspect cooling system for leaks.