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 Charge Air Cooler Upper Mounting Tab

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Install the charge air cooler radiator.
Slide the charge air cooler up to engage the upper mounting tab to the radiator.

Fig 2: Locating Charge Air Cooler Radiator Lower Right Mounting Bolt

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Install the mounting bolt to the lower right side of the charge air cooler radiator.

Fig 3: Locating Charge Air Cooler Radiator Lower Left Mounting Bolt

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NOTE: Refer to Fastener Notice .

Install the mounting bolts to the lower left side of the charge air cooler radiator.
Tighten: Tighten the bolts to 10 N.m (88 lb in).

Fig 4: Locating Radiator Upper Mounting Tabs

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Slide the condenser up to engage the upper mounting tabs into the radiator.

Fig 5: Locating Condenser Bolts

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Install the condenser bolts.
Tighten: Tighten the bolts to 10 N.m (88 lb in).

Fig 6: View Of Air Dam - 2.0L

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Install the air dam with the pushpin fasteners.

Fig 7: View Of Inlet Hose & Auxiliary Water Pump

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Install the auxiliary water pump inlet hose to the charge air cooler radiator.
Using GE-47622 compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator. See Special Tools .
Install the charge air cooler radiator inlet hose to the charge air cooler radiator.

Fig 8: View Of Charge Air Cooler Radiator Inlet Hose

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Using GE-47622 compress the charge air cooler radiator inlet hose clamp at the charge air cooler radiator. See Special Tools .
Fill the cooling system. Refer to Draining and Filling Cooling System - Charge Air Cooling System .