S10 Pickup, Sonoma 2000-2004

Removal & Installation

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2.2L Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Remove the radiator inlet hose clamp from the water outlet housing.
  6.  
  7. Remove the radiator inlet hose.
  8.  
  9. Remove the water outlet housing mounting bolts.
  10.  
  11. Remove the water outlet housing from the engine.
  12.  
  13. Remove thermostat and O-ring seal.
  14.  
  15. Clean all of the parts.
  16.  
  17. Clean all of the sealing surfaces.

    Click image to see an enlarged view

    Fig. Thermostat location-2.2L engine

  18.  

To install:

  1. Install the thermostat and the O-ring seal to the engine.
  2.  
  3. Install the water outlet housing to the engine.
  4.  
  5. Install the water outlet housing mounting blots. Tighten the water outlet housing mounting bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the upper radiator inlet hose to the water outlet housing.
  8.  
  9. Install the radiator hose clamp to the water outlet housing.
  10.  
  11. Inspect coolant for leaks.
  12.  
  13. Connect the negative battery cable.
  14.  

4.3L Engine



  1. Disconnect the negative battery cable.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Remove the throttle body bracket nuts and reposition the bracket.
  8.  
  9. Remove the water outlet housing mounting bolts.
  10.  
  11. Remove the water outlet housing from the lower intake manifold and set aside.
  12.  
  13. Remove the gasket or O-ring.
  14.  
  15. Remove the thermostat.
  16.  
  17. Clean all the sealing surfaces of the water outlet housing.
  18.  
  19. Clean the sealing surface on the lower intake manifold.

    Click image to see an enlarged view

    Fig. Thermostat location-4.3L engine

  20.  

To install:

  1. Install the thermostat.
  2.  
  3. Install a new gasket or O-ring.
  4.  
  5. Install the water outlet housing to the lower intake manifold.
  6.  
  7. Install the water outlet housing mounting bolts. Tighten water outlet housing mounting bolts to 14 ft. lbs. (19 Nm).
  8.  
  9. Install the throttle body bracket to the throttle body.
  10.  
  11. Install the throttle body bracket nuts. Tighten the throttle body bracket nuts to 89 inch lbs. (10 Nm).
  12.  
  13. Fill the cooling system.
  14.  
  15. Inspect for coolant leaks.
  16.  
  17. Connect the negative battery cable.
  18.  

 
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