GM 10038440 Housing & Flange Asm

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The thermostat housing is located on the left upper end of the cylinder head on the 2.5L four-cylinder engine and on the upper right end, between the cylinder heads, of the 2.BL V6 engine. The removal procedures are the same for both. Remove the thermostat housing cap by pushing down firmly and twisting it clockwise. Grasp the handle of the thermostat and gently pull it out of the housing. Wipe out the thermostat housing with a clean rag. Wipe off the thermostat O-ring and lubricate it with white grease. Check the thermostat to determine whether it must be replaced. Install the thermostat by pushing it down into the housing until it is properly seated. Install the thermostat housing cap. If you are replacing a damaged thermostat housing or a leaking thermostat housing gasket, repeat the previous steps, then disconnect the radiator hose from the housing. Note: This is the highest point in the cooling system, but some coolant will be spilled when removing the hose. It's a good idea to have some rags ready to mop up the spilled coolant. Disconnect the coolant temperature sensor wire from the sensor. If you are replacing the gasket, leave the coolant temperature sensor attached to the thermostat housing. If you are replacing the thermostat housing, remove the coolant temperature sensor from the housing. Caution: Care must be taken when handling the coolant sensor. Damage to this sensor will affect the operation of the fuel injection system. Unbolt and remove the thermostat housing. Scrape all old gasket material from the mating surface of the cylinder head. Inspect the housing for damage on the outside and corrosion on the inside. Apply a thin coat of RTV sealant to both sides of the new gasket and position it on the thermostat housing flange. Install the thermostat housing and gasket and tighten the bolts securely. Wrap the threads of the coolant temperature sensor with Teflon tape, install it in the thermostat housing and tighten it securely. Reconnect the coolant temperature sensor wire. Top up the cooling system with fresh coolant. Install the thermostat and the thermostat housing pressure cap. Start the engine and check the new thermostat housing gasket for leaks.

You can remove the thermostat and inspect it for excessive corrosion and damage.

Start the engine and check the new thermostat housing gasket for leaks. This will help confirm that the installation has been completed successfully.