Chevrolet Cobalt Service & Repair Manual: Thermostat, Replace

Chevrolet Cobalt Service & Repair Manual / Air Conditioning & Heater / Component Replacement & Adjustment / 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.
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. Reverse procedure to install. Torque thermostat housing 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

    Temperature Valve Actuator, Replace
    The key should be in the OFF position when connecting the electrical connectors to ensure proper calibration. 1. Remove fuse labeled HVAC CTRL (BATT). ...

    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. ...

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