Cobalt 2006-2008, G5 2007

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

  2.  
  3. Raise and support the vehicle.
  4.  
  5. Drain the cooling system.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the air cleaner outlet resonator.
  10.  
  11. Remove the radiator inlet hose from the radiator using special tool, J 38185.
  12.  
  13. Remove the radiator outlet hose from the radiator using special tool, J 38185.
  14.  
  15. If equipped with an automatic transaxle, clean the upper transaxle oil cooler line connection point and remove the line from the radiator.
  16.  
  17. If equipped with an automatic transaxle:
    1. Remove the left front wheelhouse liner.
    2.  
    3. Remove the left engine splash shield.
    4.  
    5. Clean the lower transaxle oil cooler line connection point and remove the line from the radiator.

      Click image to see an enlarged view

      Fig. Removing left front wheelhouse liner to access lower automatic transmission line



      Click image to see an enlarged view

      Fig. Removing the air dam push-in retainer

    6.  

  18.  
  19. Remove 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 and support the cooling fan assembly.
  20.  
  21. Remove the air dam push-in retainer.
  22.  
  23. Remove the air dam.
  24.  
  25. Remove the charge air cooler, if equipped.
  26.  
  27. If equipped with air conditioning, remove the condenser bolts.
    NOTE
    You are not required to discharge the A/C system.

  28.  
  29. Slide the condenser down to disengage the upper mounting tabs from the radiator. Position the condenser away from the radiator and support the condenser.
  30.  
  31. Remove the right and left radiator side baffles.
  32.  
  33. Remove the right engine splash shield to radiator mount push-in retainer.
  34.  
  35. If equipped with a manual transaxle, remove the left engine splash shield to radiator mount push-in retainer.
  36.  
  37. Remove the lower radiator mounts, brackets, and bolts.

    Click image to see an enlarged view

    Fig. Removing right and left radiator side baffles



    Click image to see an enlarged view

    Fig. Removing lower radiator mounts, brackets, and bolts

  38.  
  39. Tilt the condenser forward in the vehicle. Tilt the cooling fan assembly rearward in the vehicle.
  40.  
  41. Remove the radiator assembly from the vehicle.
  42.  
  43. Remove the upper radiator air baffle.
  44.  

To install:

  1. Verify that the upper radiator mounts are installed in the vehicle.
  2.  
  3. Install the upper radiator air baffle.
  4.  
  5. Tilt the condenser forward in the vehicle. Tilt the cooling fan assembly rearward in the vehicle.
  6.  
  7. Install the radiator assembly into the vehicle.
  8.  
  9. 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. If equipped with a manual transaxle, install the left engine splash shield to radiator mount push-in retainer.
  16.  
  17. If equipped with air conditioning, install the right and left radiator side baffles.
  18.  
  19. Slide the condenser up to engage the upper mounting tabs into the radiator.
  20.  
  21. Install the condenser bolts. Tighten the bolts to 88 inch lbs. (10 Nm).
  22.  
  23. Install the charge air cooler, if equipped.
  24.  
  25. Install the air dam and push-in retainers.
  26.  
  27. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the fan shroud onto the radiator.
  28.  
  29. If equipped with an automatic transaxle:
    1. Install the lower transaxle oil cooler line and seal to the radiator. Tighten the transaxle oil cooler line to 15 ft. lbs. (20 Nm).
    2.  
    3. Install the left engine splash shield.
    4.  
    5. Install the left front wheelhouse liner.
    6.  

  30.  
  31. Lower the vehicle.
  32.  
  33. If equipped with an automatic transaxle, install the upper transaxle oil cooler line and seal to the radiator. Tighten the transaxle oil cooler line to 15 ft. lbs. (20 Nm).
  34.  
  35. Install the radiator outlet hose to the radiator.
  36.  
  37. Reposition the hose clamp to secure the hose using special tool, J 38185.
  38.  
  39. Install the radiator inlet hose to the radiator.
  40.  
  41. Reposition the hose clamp to secure the hose using special tool, J 38185.
  42.  
  43. Install the air cleaner outlet resonator.
  44.  
  45. Fill the cooling system.
  46.  
  47. If equipped with an automatic transaxle, add fluid to the transaxle as necessary.
  48.  

 
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