Cobalt 2006-2008, G5 2007

Removal & Installation

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2.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the engine fan electrical connectors.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the engine fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the engine fan assembly away from the radiator.

    Click image to see an enlarged view

    Fig. Removing the air dam push-in retainer

  8.  
  9. Remove or disconnect the following:

    The air dam push-in retainers
     
    The air dam
     
    The right engine splash shield to radiator mount push-in retainer
     
    The left engine splash shield to radiator mount push-in retainer
     

  10.  
  11. Remove the charge air cooler radiator:
    1. Drain the charge air cooling system.
    2.  
    3. Using special tool, GE-47622, compress the charge air cooler radiator inlet hose clamp at the charge air cooler radiator.

      Click image to see an enlarged view

      Fig. Removing the auxiliary water pump inlet hose from charge air cooler radiator-2.0L engine

    4.  
    5. Remove the charge air cooler radiator inlet hose from the charge air cooler radiator.
    6.  
    7. Using special tool, GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator.
    8.  
    9. Remove the auxiliary water pump inlet hose from the charge air cooler radiator.
    10.  
    11. Remove the condenser bolts.
    12.  
    13. Slide the condenser down to disengage the upper mounting tabs from the radiator.
    14.  
    15. Reposition the condenser to allow access to the charge air cooler radiator.
    16.  
    17. Remove the mounting bolt from the lower left side of the charge air cooler radiator.
    18.  
    19. Remove the mounting bolt from the lower right side of the charge air cooler radiator.
    20.  
    21. Slide the charge air cooler down to disengage the upper mounting tab from the radiator.
    22.  
    23. Remove the charge air cooler radiator.
    24.  

  12.  
  13. Remove the lower radiator mount, brackets, and bolts. Support the radiator and condenser.
  14.  
  15. Tilt the radiator and condenser forward in the vehicle.
  16.  
  17. Remove the engine fan assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Removing the engine fan assembly-2.0L engine

  18.  

To install:

  1. Install the engine fan assembly into the vehicle.
  2.  
  3. Restore the radiator and condenser to the original position.
  4.  
  5. Install the charge air cooler radiator:
    1. Slide the charge air cooler up to engage the upper mounting tab to the radiator.
    2.  
    3. Install the mounting bolt to the lower right side of the charge air cooler radiator.
    4.  
    5. Install the mounting bolts to the lower left side of the charge air cooler radiator. Tighten the bolts to 88 inch lbs. (10 Nm).
    6.  
    7. Slide the condenser up to engage the upper mounting tabs into the radiator.
    8.  
    9. Install the condenser bolts. Tighten the bolts to 88 inch lbs. (10 Nm).
    10.  
    11. Install the air dam with the pushpin fasteners.
    12.  
    13. Install the auxiliary water pump inlet hose to the charge air cooler radiator.
    14.  
    15. Using special tool, GE-47622, compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator.
    16.  
    17. Install the charge air cooler radiator inlet hose to the charge air cooler radiator.
    18.  
    19. Using special tool, GE-47622, compress the charge air cooler radiator inlet hose clamp at the charge air cooler radiator.
    20.  

  6.  
  7. Verify that the upper radiator mounts are installed in the vehicle.
  8.  
  9. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts.
  10.  
  11. Install the lower radiator mounts, brackets, and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  12.  
  13. Install the right engine splash shield to radiator mount push-in retainer.
  14.  
  15. Install the left engine splash shield to radiator mount push-in retainer.
  16.  
  17. Install the air dam and the push-in retainers.
  18.  
  19. Align the engine fan shroud retaining features to the radiator. Pull down on the engine fan assembly to snap the shroud onto the radiator.
  20.  
  21. Lower the vehicle.
  22.  
  23. Connect the engine fan electrical connectors.
  24.  
  25. Fill the cooling system.
  26.  

2.2L & 2.4L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the cooling fan electrical connector.
  4.  
  5. Remove the cooling fan wire from the fan shroud.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove or disconnect the following:

    The cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator
     
    The air dam push-in retainers
     
    The air dam
     
    The right engine splash shield to radiator mount push-in retainer
     
    The left engine splash shield to radiator mount push-in retainer
     
    The lower radiator mount, brackets, and bolts. Support the radiator and condenser
     

  10.  
  11. Tilt the radiator and condenser forward in the vehicle. Remove the cooling fan assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Removing the engine fan assembly-2.2L & 2.4L engines

  12.  

To install:

  1. Tilt the radiator and condenser forward in the vehicle. Install the cooling fan assembly into the vehicle.
  2.  
  3. Verify that the upper radiator mounts are installed in the vehicle.
  4.  
  5. Raise the radiator and condenser into position. Verify that the upper radiator mount pins align with the upper radiator mounts.
  6.  
  7. Install or connect the following:

    The lower radiator mounts, brackets, and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm)
     
    The right engine splash shield to radiator mount push-in retainer
     
    The left engine splash shield to radiator mount push-in retainer
     
    The air dam and the push-in retainers
     
    Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the shroud onto the radiator
     

  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the cooling fan electrical connector.
  12.  
  13. Install the cooling fan wire to the fan shroud.
  14.  

 
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