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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 41 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR REPLACEMENT (L81)INSTALLATION 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 L300. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing/Installing Gaskets Separating Upper & Lower Radiator From Condenser
    GM894311Courtesy of GENERAL MOTORS CORP.
  1. Install the gaskets between the upper and lower radiator and the condenser.
    2. Fig 2: Installing Radiator Lower Mounting Pins To Rubber Mounts
    GM894720Courtesy of GENERAL MOTORS CORP.
  2. Install the radiator lower mounting pins into the rubber mounts.
    3. Fig 3: Removing/Installing Radiator Coolant Air Bleed Hose From Radiator
    GM894532Courtesy of GENERAL MOTORS CORP.
  3. Install the radiator coolant air bleed hose to the radiator.
  4. Install the radiator coolant air bleed hose clamp at the 1 o'clock position.
  5. Install the wiring clips to the upper radiator mounting bracket.
    6. Fig 4: Removing/Installing Radiator Upper Mount Bracket & Rubber Mounts
    GM898634Courtesy of GENERAL MOTORS CORP.
  6. Position the upper radiator mounts over the upper pins.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the radiator bracket bolts

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

  8. Install the wiring clips to the upper radiator mount bracket.
    9. Fig 5: Positioning Condenser Tabs Under Radiator Tabs
    GM894033Courtesy of GENERAL MOTORS CORP.
  9. Position the condenser tabs under the radiator tabs.
  10. Install the condenser to radiator bolts.

    Tighten:  Tighten the bolts to 4 N.m (35 lb in).

    11. Fig 6: Removing/Installing Gaskets Separating Upper & Lower Radiator From Condenser
    GM894311Courtesy of GENERAL MOTORS CORP.
  11. Install the lower radiator to the condenser gasket.
    12. Fig 7: Removing/Installing Condenser Block Bolt From Radiator End Tank
    GM894382Courtesy of GENERAL MOTORS CORP.
  12. Install the bolt which secures the condenser block to the radiator end tank.

    Tighten:  Tighten the bolt to 4 N.m (35 lb in).

  13. Remove the condenser support wire or the plastic tie.
    14. Fig 8: Removing/Installing Lower Transaxle Cooler Line From Radiator
    GM893763Courtesy of GENERAL MOTORS CORP.
  14. Remove the cap and install the lower transaxle cooler line to radiator.

    Tighten:  Tighten the cooler line to 4 N.m (35 lb in).

    15. Fig 9: Removing/Installing Lower Radiator Hose From Radiator
    GM893929Courtesy of GENERAL MOTORS CORP.
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.