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:

Manual Transmission
The vehicle may be equipped with a 5-speed or 6-speed manual transmission. Caution Shifting the vehicle initially into any gear other than 1 (First) or R (Reverse) can damage the clutch. Shift the manual transmission in the proper sequence, and time the gear shifting with the accelerator to ...

Engine Oil Cooler Replacement
Removal Procedure Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection. Drain engine coolant. Refer to Cooling System Draining and Filling Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement ...

Timing Belt Adjustment
Special Tools EN-652 Flywheel Holder EN-6333 Locking Pin EN-6340 Locking Tool EN-6628-A Locking Tool EN-45059 Torque Angle Sensor Kit For equivalent regional tool, refer to Special Tools. Removal Procedure Remove the timing belt upper front cover. Refer to Timing Bel ...

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