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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 41 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE TANK REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Removal Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Removal 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 Surge Tank Return Hose
    GM893750Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Drain the coolant. Refer to Draining and Filling Cooling System .
  3. Remove the clamp which secures the return hose to the surge tank.
  4. Remove the return hose from the surge tank.
    5. Fig 2: Removing/Installing Surge Tank Coolant Air Bleed Hose
    GM893755Courtesy of GENERAL MOTORS CORP.
  5. Remove the clamp which secures the coolant air bleed hose to the surge tank.
  6. Remove the coolant air bleed hose.
    7. Fig 3: Removing/Installing Rear Surge Tank Attachment Clip
    GM893758Courtesy of GENERAL MOTORS CORP.
  7. Remove the rear surge tank attachment clip.
    8. Fig 4: Separating Surge Tank From Mounting Tabs
    GM893760Courtesy of GENERAL MOTORS CORP.
  8. Remove the surge tank from the mounting tabs by rotating forward and inward.
  9. Disconnect the low coolant level sensor electrical connector.
  10. Remove the surge tank from the vehicle.
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.