Aveo 2004-2005

Removal & Installation

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CAUTION
As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal of the pressure cap while the engine is hot and pressure is high will cause the solution to boil instantaneously -- possibly with explosive force -- spewing the solution over the engine, fenders and the person removing the cap.

  1. Drain the coolant.
  2.  
  3. Disconnect the upper radiator hose from the thermostat housing.
  4.  
  5. Disconnect the throttle body coolant inlet hose from the thermostat housing.
  6.  
  7. Remove the thermostat bolts.
  8.  
  9. Remove the thermostat housing.
  10.  
  11. Remove the thermostat with the gasket.
  12.  
  13. Inspect the gasket for cracks or other damage.
  14.  
  15. Inspect the valve seat for foreign matter that could prevent the valve from seating properly.
  16.  
  17. Inspect the thermostat for proper operation.

    Click image to see an enlarged view

    Fig. Thermostat with bolts and housing

  18.  

To install:

  1. Install the thermostat with the bolts and the thermostat housing.
  2.  
  3. Tighten the mounting bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Secure the upper radiator hose to the thermostat housing with a hose clamp.
  6.  
  7. Connect the throttle body coolant inlet hose to the thermostat housing.
  8.  
  9. Refill the engine cooling system.
  10.  


CAUTION
As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal of the pressure cap while the engine is hot and pressure is high will cause the solution to boil instantaneously -- possibly with explosive force -- spewing the solution over the engine, fenders and the person removing the cap.

  1. Drain the coolant.
  2.  
  3. Disconnect the upper radiator hose from the thermostat housing.
  4.  
  5. Disconnect the throttle body coolant inlet hose from the thermostat housing.
  6.  
  7. Remove the thermostat bolts.
  8.  
  9. Remove the thermostat housing.
  10.  
  11. Remove the thermostat with the gasket.
  12.  
  13. Inspect the gasket for cracks or other damage.
  14.  
  15. Inspect the valve seat for foreign matter that could prevent the valve from seating properly.
  16.  
  17. Inspect the thermostat for proper operation.

    Click image to see an enlarged view

    Fig. Thermostat with bolts and housing

  18.  

To install:

  1. Install the thermostat with the bolts and the thermostat housing.
  2.  
  3. Tighten the mounting bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Secure the upper radiator hose to the thermostat housing with a hose clamp.
  6.  
  7. Connect the throttle body coolant inlet hose to the thermostat housing.
  8.  
  9. Refill the engine cooling system.
  10.  

 
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