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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 189 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSCOOLANT CROSSOVER PIPE REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2005 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Crossover Pipe & Crossover Pipe Bolts
    GM1237801Courtesy of GENERAL MOTORS CORP.
  1. Clean and dry the area before installing new seals.
  2. Install the crossover pipe.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the crossover pipe bolts.

    Tighten:  Tighten the crossover pipe bolts to 22 N.m (16 lb. ft.).

  4. Install the thermostat and thermostat housing.

    Tighten:  Tighten the thermostat housing bolts to 12 N.m (106 lb. in.).

  5. Connect the coolant hoses at the crossover pipe.
  6. Connect the wiring harness ground terminal to the crossover pipe.

    Tighten:  Tighten the nut to 12 N.m (106 lb. in.).

    7. Fig 2: Installing ECT Sensor
    GM1237580Courtesy of GENERAL MOTORS CORP.
  7. Apply thread sealant (Saturn P/N 21485277) Loctite™ 242 threadlocker, or equivalent, to sensor threads.
  8. Install the ECT sensor.

    Tighten:  Tighten the ECT sensor to 18 N.m (13 lb. ft.).

  9. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
  10. Install the battery. Refer to Battery Replacement in Engine Electrical.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.

    Tighten:  Tighten the battery terminal bolt to 17 N.m (13 lb. ft.).

  12. Fill the coolant. Refer to Draining and Filling Cooling System .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.