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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 697 (Engine Cooling System) >> Repair Instructions >> Radiator Replacement - Charge Air Cooler >> Removal Procedure

Removal 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.
  1. Drain the charge air cooling system. Refer to Draining and Filling Cooling System - Charge Air Cooling System .
    2. Fig 1: View Of Charge Air Cooler Radiator Inlet Hose
    GM1382071Courtesy of GENERAL MOTORS CORP.
  2. Using GE-47622  compress the charge air cooler radiator inlet hose clamp at the charge air cooler radiator. See Special Tools .
  3. Remove the charge air cooler radiator inlet hose from the charge air cooler radiator.
    4. Fig 2: View Of Inlet Hose & Auxiliary Water Pump
    GM1382066Courtesy of GENERAL MOTORS CORP.
  4. Using GE-47622  compress the auxiliary water pump inlet hose clamp at the charge air cooler radiator. See Special Tools .
  5. Remove the auxiliary water pump inlet hose from the charge air cooler radiator.
    6. Fig 3: View Of Air Dam - 2.0L
    GM1413270Courtesy of GENERAL MOTORS CORP.
  6. Remove the pushpin fasteners from the air dam.
  7. Remove the air dam.
    8. Fig 4: Locating Condenser Bolts
    GM877658Courtesy of GENERAL MOTORS CORP.
  8. Remove the condenser bolts.
    9. Fig 5: Locating Radiator Upper Mounting Tabs
    GM877659Courtesy of GENERAL MOTORS CORP.
  9. Slide the condenser down to disengage the upper mounting tabs from the radiator.
  10. Reposition the condenser to allow access to the charge air cooler radiator.
    11. Fig 6: Locating Charge Air Cooler Radiator Lower Left Mounting Bolt
    GM1413203Courtesy of GENERAL MOTORS CORP.
  11. Remove the mounting bolt from the lower left side of the charge air cooler radiator.
    12. Fig 7: Locating Charge Air Cooler Radiator Lower Right Mounting Bolt
    GM1413202Courtesy of GENERAL MOTORS CORP.
  12. Remove the mounting bolt from the lower right side of the charge air cooler radiator.
    13. Fig 8: View Of Charge Air Cooler Upper Mounting Tab
    GM1402987Courtesy of GENERAL MOTORS CORP.
  13. Slide the charge air cooler down to disengage the upper mounting tab from the radiator.
  14. Remove the charge air cooler radiator.
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