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. Drain the cooling system.

    Click image to see an enlarged view

    Fig. Location of radiator surge tank outlet hose clamp & oil cooler inlet and outlet hose clamps at the thermostat cover-2.0L engine

  4.  
  5. Reposition the radiator surge tank outlet hose clamp (1) at the thermostat cover.
  6.  
  7. Remove the radiator surge tank outlet hose from the thermostat cover.
  8.  
  9. Reposition the oil cooler inlet and outlet hose clamps (2) and (3) at the thermostat cover.
  10.  
  11. Remove the oil cooler inlet and outlet hoses from the thermostat cover.
  12.  
  13. Remove the thermostat cover bolts and cover.
  14.  
  15. Remove the thermostat.
  16.  
  17. Remove and discard the thermostat cover O-ring seal.

    Click image to see an enlarged view

    Fig. Removing the thermostat cover bolts, cover, thermostat, and O-ring seal-2.0L engine

  18.  

To install:

  1. Install or connect the following:

    A NEW thermostat cover O-ring seal into the recess groove
     
    The thermostat
     
    The thermostat cover bolts and tighten to 89 inch lbs. (10 Nm)
     
    The oil cooler inlet and outlet hoses to the thermostat cover
     
    The oil cooler inlet and outlet hose clamps at the thermostat cover
     
    The radiator surge tank outlet hose to the thermostat cover
     
    The radiator surge tank outlet hose clamp at the thermostat cover
     

  2.  
  3. Fill the cooling system and check for leaks.
  4.  

2.2L & 2.4L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold cover:
    1. Remove the engine oil fill cap.
    2.  
    3. Grasp the intake manifold cover by the lower right inboard corner and pull up to disengage the cover from the stud.
    4.  
    5. Grasp the intake manifold cover by the upper left corner and pull up to disengage the cover from the stud.
    6.  
    7. Remove the intake manifold cover.

      Click image to see an enlarged view

      Fig. Location of radiator outlet hose clamp (1) at thermostat cover for the removal of the radiator outlet hose from the thermostat cover-2.2L & 2.4L engines

    8.  

  4.  
  5. Drain the cooling system.
  6.  
  7. Reposition the radiator outlet hose clamp at the thermostat cover.
  8.  
  9. Remove the radiator outlet hose from the thermostat cover.
  10.  
  11. Reposition the radiator surge tank outlet hose clamp at the thermostat cover.
  12.  
  13. Remove the radiator surge tank outlet hose from the thermostat cover.
  14.  
  15. Reposition the radiator outlet hose clamp (1) at the thermostat cover.
  16.  
  17. Remove the radiator outlet hose from the thermostat cover.
  18.  
  19. Remove the thermostat cover bolts and cover.
  20.  
  21. Remove the thermostat.
  22.  
  23. Remove and discard the thermostat cover O-ring seal.

    Click image to see an enlarged view

    Fig. Location of thermostat cover bolts for removal of the thermostat and thermostat cover O-ring seal-2.2L & 2.4L engines

  24.  

To install:

  1. Install or connect the following:

    A NEW thermostat cover O-ring seal
     
    The thermostat
     
    The thermostat cover bolts. Tighten the bolts to 89 inch lbs. (10 Nm)
     
    The radiator outlet hose to the thermostat cover
     
    The radiator outlet hose clamp at the thermostat cover
     
    The radiator surge tank outlet hose to the thermostat cover
     
    The radiator surge tank outlet hose clamp at the thermostat cover
     
    The radiator outlet hose to the thermostat cover
     
    The radiator outlet hose clamp at the thermostat cover
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Install the intake manifold cover:
    1. Place the intake manifold cover onto the engine over the studs.
    2.  
    3. Push down on the intake manifold cover directly over the lower right stud in order to engage the cover to the stud.
    4.  
    5. Push down on the intake manifold cover directly over the upper left stud in order to engage the cover to the stud.
    6.  
    7. Install the engine oil fill cap.
    8.  

  6.  

 
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