G6 2005-2007

Removal & Installation

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2.4L Engine



  1. Drain the cooling system.
    NOTE
    A drain has been provided at the bottom of the water pump for engine block coolant drainage.

  2.  
  3. Remove the water pump drain plug and drain the coolant from the engine block at the water pump drain.
  4.  
  5. Lower the vehicle.
  6.  
  7. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  8.  
  9. Disconnect the heated oxygen sensor (HO2S) electrical connector clip from the bracket.
  10.  
  11. Remove the ECT sensor.
  12.  
  13. If the vehicle is not equipped an engine oil cooler proceed with the following steps, otherwise proceed to step 12.
  14.  
  15. Reposition the radiator outlet hose clamp at the surge tank.
  16.  
  17. Remove the radiator outlet hose from the surge tank.
  18.  
  19. Reposition the radiator outlet hose clamp at the thermostat housing.
  20.  
  21. Remove the radiator outlet hose from the thermostat housing.
  22.  
  23. If the vehicle is equipped with an engine oil cooler, reposition the surge tank outlet hose clamp at the thermostat housing.
  24.  
  25. Remove the surge tank outlet hose from the thermostat housing.
  26.  
  27. Reposition the radiator outlet hose clamp at the thermostat housing.
  28.  
  29. Remove the radiator outlet hose from the thermostat housing.
  30.  
  31. Remove the exhaust heat shield bolts.
  32.  
  33. Remove the exhaust heat shield.
  34.  
  35. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
  36.  
  37. Disconnect the heater inlet and outlet hoses from the thermostat housing pipes.
  38.  
  39. Remove the thermostat housing bolts.
  40.  
  41. Twist the water transfer pipe while pulling in order to remove it from the water pump.
  42.  
  43. Remove the thermostat housing from the vehicle.
  44.  
  45. Remove the water transfer pipe from the thermostat housing, if necessary.
  46.  
  47. Remove and discard the water transfer pipe O-ring seals, if necessary.
  48.  
  49. Remove the thermostat housing cover bolts and cover, if necessary.
  50.  
  51. Remove the thermostat, if necessary.
  52.  
  53. Remove and discard the thermostat housing O-ring seal, if necessary.
  54.  
  55. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.
  56.  

To install:

  1. Install a NEW thermostat housing cover O-ring seal into the recess groove.
  2.  
  3. Install the thermostat, if necessary.
  4.  
  5. Install the thermostat housing cover bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install a NEW thermostat housing to engine O-ring seal onto the thermostat housing.
  8.  
  9. Load the thermostat housing assembly into position while the vehicle is lowered.
  10.  
  11. The water feed pipe seals can be lightly lubricated with coolant to aid during installation.
  12.  
  13. Install NEW O-ring seals onto the water feed pipe.
  14.  
  15. Lubricate the O-rings with coolant.
  16.  
  17. Install the water feed pipe into the thermostat housing aligning locator tab.
  18.  
  19. Align the water pipe to water pump.
  20.  
  21. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
  22.  
  23. Position the thermostat housing against the engine.
  24.  
  25. Install the thermostat housing bolts and tighten to 89 inch lbs. (10 Nm).
  26.  
  27. Connect the heater inlet and outlet hoses to the thermostat housing pipes.
  28.  
  29. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
  30.  
  31. Install the exhaust heat shield.
  32.  
  33. Install the exhaust heat shield bolts and tighten to 17 ft. lbs. ( 23 Nm).
  34.  
  35. If the vehicle is equipped with an engine oil cooler proceed with the following steps.
  36.  
  37. Install the radiator outlet hose to the thermostat housing.
  38.  
  39. Position the radiator outlet hose clamp at the thermostat housing.
  40.  
  41. Install the surge tank outlet hose to the thermostat housing.
  42.  
  43. Position the surge tank outlet hose clamp at the thermostat housing.
  44.  
  45. If the vehicle is not equipped an engine oil cooler, install the radiator outlet hose to the thermostat housing.
  46.  
  47. Position the radiator outlet hose clamp at the thermostat housing.
  48.  
  49. Install the radiator outlet hose to the surge tank.
  50.  
  51. Position the radiator outlet hose clamp at the surge tank.
  52.  
  53. Apply sealant to the threads of the ECT sensor.
  54.  
  55. Install the ECT sensor and tighten to 15 ft. lbs. (20 Nm).
  56.  
  57. Connect the ECT sensor electrical connector.
  58.  
  59. Connect the HO2S electrical connector clip to the bracket.
  60.  
  61. Apply sealant to the water pump drain plug.
  62.  
  63. Install the water pump drain plug and tighten to 15 ft. lbs. ( 20 Nm).
  64.  
  65. Verify the drain valves at the radiator and water pump are closed.
  66.  
  67. Fill the cooling system.
  68.  
  69. Verify the repair and inspect for any leaks.
  70.  

3.5L & 3.9L Engines



  1. Drain the cooling system.
  2.  
  3. Remove the air cleaner outlet duct.
  4.  
  5. Disconnect the surge tank hose from the coolant outlet.
  6.  
  7. Remove the thermostat housing to intake manifold bolts.
  8.  
  9. Remove the thermostat housing outlet and thermostat.
  10.  

To install:

  1. Install the thermostat and housing outlet.
  2.  
  3. Install the thermostat housing bolts and tighten to 18 ft. lbs. (25 M,).
  4.  
  5. Install the air cleaner outlet duct.
  6.  
  7. Fill the cooling system.
  8.  
  9. Inspect the system for leaks.
  10.  

3.6L Engine



  1. Partially drain the cooling system.
    WARNING
    Do NOT separate the upper and lower intake manifolds.

  2.  
  3. Remove the upper intake manifold with the lower intake manifold. Refer to Lower Intake Manifold Replacement.
  4.  
  5. Disconnect the surge tank hose from the thermostat.
  6.  
  7. Remove the coolant pipe/thermostat housing bolt 
  8.  
  9. Remove the coolant pipe bolt.
  10.  
  11. Remove the coolant inlet pipe from the thermostat housing.
  12.  
  13. Remove and discard the coolant pipe O-ring seal.
  14.  
  15. Remove the thermostat bolts.
  16.  
  17. Remove the thermostat and discard the thermostat seal.

    Click image to see an enlarged view

    Fig. Thermostat removal 3.6L engine

  18.  

To install:

  1. Install the thermostat with a new thermostat seal.
  2.  
  3. Install the thermostat bolts and tighten to 89 inch. lbs. (10 Nm).
  4.  
  5. Install the coolant pipe, new seal, and fasteners (1 and 3).
  6.  
  7. Install the surge tank hose to the thermostat.
  8.  
  9. Install the upper intake manifold with the lower intake manifold.
  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Inspect the system for leaks.
  14.  

 
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