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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 623 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE TANK 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 2007 Pontiac G5 Pursuit, 2007 Pontiac G5, and 2007 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Coolant Level Sensor Electrical Connector
    GM873721Courtesy of GENERAL MOTORS CORP.
  1. Install the surge tank.
  2. Connect the coolant level sensor electrical connector.
    3. Fig 2: Identifying Surge Tank Nut
    GM1548520Courtesy of GENERAL MOTORS CORP.
  3. With the surge tank raised, install the surge tank outlet hose.
  4. Reposition the hose clamp using J 38185  to secure the hose. See Special Tools .
    5. NOTE: Refer to Fastener Notice .
  5. Install the surge tank nut.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

    6. Fig 3: View Of Engine Compartment Component Locations
    GM889782Courtesy of GENERAL MOTORS CORP.
  6. Set the underhood junction block bracket into position.
  7. Install the underhood junction block bracket nuts (1, 2).

    Tighten:  Tighten the nuts to 10 N.m (88 lb in).

  8. Install the underhood junction block bracket bolt (3).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    9. Fig 4: View Of Surge Tank Inlet Hose
    GM873719Courtesy of GENERAL MOTORS CORP.
  9. Install the surge tank inlet hose to the surge tank.
  10. Reposition the hose clamp using J 38185  to secure the hose. See Special Tools .
  11. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ))  or Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5))  or Draining and Filling Cooling System (GE 47716 Fill) .
RENDER: 1.0x

NO RELATED

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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.