Chevrolet Cobalt Service & Repair Manual: Water Pump, Replace

Chevrolet Cobalt Service & Repair Manual / Air Conditioning & Heater / Component Replacement & Adjustment / Water Pump, Replace

1. Remove intake manifold cover.
2. Drain cooling system into suitable container. A drain plug is located at the bottom of water pump.
3. Disconnect Engine Coolant Temperature (ECT) sensor electrical connector.
4. Remove Heated Oxygen Sensor (HO2S) electrical connector clip from thermostat housing.
5. Remove ECT sensor, Fig. 1.
6. Reposition radiator outlet hose clamp at thermostat cover.
7. Remove radiator outlet hose from thermostat cover.
8. Remove exhaust heat shield studs.
9. Remove exhaust heat shield.
10. Reposition heater inlet and outlet hose clamps at thermostat housing pipes.
11. Disconnect heater inlet and outlet hoses from thermostat housing pipes.
12. Raise and support vehicle.
13. Remove thermostat housing bolts, Fig. 2.
14. Remove thermostat from vehicle.
15. Remove water transfer pipe from thermostat housing.
16. Remove and discard water transfer pipe O-ring seals, Fig. 3.
17. Remove thermostat cover bolts and cover.
18. Remove thermostat.
19. Remove and discard thermostat cover O-ring seal.
20. Remove all debris and thread sealant from ECT sensor and bolt holes if housing is being re-used.
21. Remove water pump access plate from front cover, Fig. 4.
22. Remove right hand fender liner.
23. Install water pump holding tool No. J 43651, or equivalent, to sprocket and chain during water pump service. Tool must be used or the balance shaft must be re-timed.
24. Tighten bolts on water pump holding tool into threads on water pump sprocket.
25. Install access cover bolts that were removed earlier to secure water pump holding tool to front cover assembly.
26. Remove three inner water pump sprocket to water pump blots, Fig. 5.
27. Remove two outer water pump bolts, Fig. 6.
28. Remove two rear water pump bolts, Fig. 7.
29. Remove water pump. Discard water pump O-ring seal.
30. Reverse procedure to install, noting the following:
  a. Install a new water pump O-ring seal.
  b. Using suitable guide pin, then align pin with water pump holding tool, Fig. 8.
  c.
  d.
  e. Torque water pump bolts to 18 ft. lbs.
  f. Torque water pump sprocket bolts to 89 inch lbs.
  g. Torque water pump access plate bolts to 89 inch lbs.

Fig. 1 Engine coolant temperature sensor removal

Fig. 2 Engine coolant thermostat housing replacement

Fig. 3 Exploded view of thermostat cover & O-ring seal

Fig. 4 Front water pump cover access plate removal

Fig. 5 Inner water pump sprocket to water pump blot locations

Fig. 6 Outer water pump bolts

Fig. 7 Rear water pump bolts

Fig. 8 Water pump guide pin and pump installation

    Thermostat, Replace
    1. Remove intake manifold cover. 2. Drain cooling system into suitable container. A drain plug is located at the bottom of water pump. ...

    Compressor Service
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    See also:

    Chevrolet Cobalt Owners Manual. New Vehicle Break-In
    Notice: The vehicle does not need an elaborate break-in. But it will perform better in the long run if you follow these guidelines: - Do not drive at any one constant speed, fast or slow, for the first 500 miles (805 km). Do not make full-throttle starts. Do not exceed 5,000 engine rpm. Avoid ...

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