Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 860 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR SURGE 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 2010 Pontiac G5 and 2010 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

Courtesy of GENERAL MOTORS CORP.

Install the surge tank.
Connect the coolant level sensor electrical connector.

Fig 2: Identifying Surge Tank Outlet Hose

Courtesy of GENERAL MOTORS CORP.

With the surge tank raised, install the surge tank outlet hose.
Reposition the hose clamp using J 38185 to secure the hose. See Special Tools .
Install the underhood junction block and bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement

Fig 3: View Of Surge Tank Inlet Hose

Courtesy of GENERAL MOTORS CORP.

Install the surge tank inlet hose to the surge tank.
Reposition the hose clamp using J 38185 to secure the hose. See Special Tools .
Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill LE5, L61) or Cooling System Draining and Filling (Static Fill LNF) or Cooling System Draining and Filling (GE 47716 Fill) .

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.