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. Remove the thermostat housing cap and bolts.
  4.  
  5. Remove the thermostat.
  6.  
  7. Remove the oxygen sensor clip.
  8.  
  9. Remove the thermostat housing and water feed pipe retaining bolts.
    NOTE
    Twist the water feed pipe while pulling to remove it from the water pump cover.



    Click image to see an enlarged view

    Fig. Thermostat housing and feed pipe-2.0L engine

  10.  
  11. Remove the thermostat housing and water feed pipe from the water pump cover.
  12.  
  13. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.

    Click image to see an enlarged view

    Fig. Water pump removal-2.0L engine

  14.  
  15. Remove the water pump assembly.
  16.  

To install:

  1. Install the water pump assembly.
  2.  
  3. Install the water pump bolts. Finger tighten the bolts.
  4.  
  5. Tighten the water pump bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Apply sealant P/N 12378521 (Canadian P/N 88901148) to the water pump drain plug.
  8.  
  9. Install the water pump drain plug, if necessary. Tighten the water pump drain plug to 15 ft. lbs. (20 Nm).
  10.  
  11. Install the water feed tube.
  12.  
  13. Lubricate the feed tube O-ring with anti-freeze.
  14.  
  15. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
  16.  
  17. Install the thermostat housing to block bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  18.  
  19. Install the thermostat.
  20.  
  21. Install the thermostat housing cap and bolts.
  22.  

2.2L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If equipped with an automatic transaxle, remove the exhaust manifold.
  4.  
  5. Drain the cooling system.
  6.  
  7. Raise and suitably support the vehicle.
  8.  
  9. Remove the right front tire and wheel.
  10.  
  11. Remove the front fender liner.

    Click image to see an enlarged view

    Fig. Water pump access cover-2.2L engine

  12.  
  13. Remove the access plate on the water pump sprocket from the timing cover.
  14.  
  15. Install tool J 43651, or equivalent, on the water pump sprocket.
    NOTE
    Use the access plate bolts to secure the tool to the engine front cover.

  16.  
  17. Remove the bolts that secure the sprocket to the water pump.

    Click image to see an enlarged view

    Fig. Remove these 2 water pump bolts first-2.2L engine

  18.  
  19. Remove the bolt (1) that secures the water pump to the engine block.
  20.  
  21. Remove the bolt (2) that secures the engine water pump to the front cover.
  22.  
  23. Remove the feed pipe that joins the thermostat housing to the water pump.
  24.  
  25. Remove the 2 bolts that secure the water pump to the engine block.

    Click image to see an enlarged view

    Fig. Water pump removal-2.2L engine

  26.  
  27. Remove the water pump.
  28.  

To install:

  1. Use a threaded stud in the hub to align the hub to the water pump sprocket.
  2.  
  3. Install the water pump.
  4.  
  5. Install the 2 bolts that secure the water pump to the engine block. Tighten the bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the feed pipe that joins the thermostat housing to the water pump.
  8.  
  9. Install the engine front cover bolt and the bolt that secures the water pump to the engine block. Tighten the bolts to 15 ft. lbs. (20 Nm).
  10.  
  11. Install 2 of the bolts that secure the water pump sprocket to the water pump.
  12.  
  13. Remove the threaded stud.
  14.  
  15. Install the last bolt. Tighten the bolts to 62 inch lbs. (7 Nm).
  16.  
  17. Install the access plate on the water pump sprocket to the timing cover.
  18.  
  19. Install the bolts that secure the access plate to the timing cover. Tighten the bolts to 18 inch lbs. (10 Nm).
  20.  
  21. Install the front fender liner.
  22.  
  23. Install the right front tire and wheel.
  24.  
  25. If equipped with an automatic transaxle, install the exhaust manifold.
  26.  
  27. Fill the cooling system.
  28.  

2.4L 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. Removing the engine coolant temperature sensor -2.4L engine



    Click image to see an enlarged view

    Fig. Removing the thermostat housing and water feed pipe from the water pump cover-2.4L engine

  4.  
  5. Remove the engine coolant temperature sensor.
  6.  
  7. Remove the thermostat and water feed pipe retaining bolts.
    NOTE
    Twist the water feed pipe while pulling to remove it from the water pump cover.

  8.  
  9. Remove the thermostat housing and water feed pipe from the water pump cover.
  10.  
  11. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.
  12.  
  13. Remove the water pump assembly.

    Click image to see an enlarged view

    Fig. Removing the water pump bolts and water pump assembly-2.4L engine

  14.  

To install:


WARNING
Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to ensure proper sealing.

  1. Install the water pump assembly.
  2.  
  3. Install the water pump bolts. Finger tighten the bolts.
  4.  
  5. Tighten the water pump bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Apply sealant GM P/N 12346004 or equivalent to the water pump drain plug.
  8.  
  9. Install the water pump drain plug, if necessary. Tighten the water pump drain plug to 15 ft. lbs. (20 Nm).
  10.  
  11. Install the water feed tube.
  12.  
  13. Lubricate the feed tube O-ring with clean antifreeze.
  14.  
  15. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
  16.  
  17. Install the thermostat housing to block bolts and stud. Tighten the bolts to 89 inch lbs. (10 Nm).
  18.  
  19. Install the engine coolant temperature sensor by hand.
  20.  
  21. Tighten the engine coolant temperature sensor. Tighten the engine coolant temperature sensor to 15 ft. lbs. (20 Nm).
  22.  
  23. Fill the cooling system.
  24.  

 
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