Chevrolet Cobalt Service & Repair Manual: Engine Coolant Thermostat Housing R&R

Refer to Fig. 1 when performing the following procedure.
1. Partially drain the coolant system.
2. Remove the thermostat.
3. Disconnect the inlet and outlet heater hoses.
4. Remove the catalytic converter.
5. Remove the oxygen (O2) sensor.
6. Remove the charge air cooler.
7. Remove the AC evaporative emissions (EVAP) hose assembly and the rear condenser tube.
8. Disconnect the brake booster vacuum hose and reposition.
9. Disconnect the shifter bracket from the transmission and reposition. Leave the cables attached.
10. Remove the turbo exhaust pipe heat shield bolts (1) and shield (2), Fig. 2.
11. Remove the turbocharger coolant return pipe.
12. Disconnect the coolant temperature sensor harness connector.
13. Remove thermostat housing and water inlet seal.
14. Reverse procedure to install, noting the following:
  a. Torque thermostat housing bolts to 89 inch lbs.
  b. Torque turbocharger coolant return pipe banjo bolts to 26 ft. lbs.
  c. Torque turbocharger exhaust pipe elbow nuts to 37 ft. lbs.
  d. Torque turbocharger brace bolts and nuts to 43 ft. lbs.
  e. Torque turbocharger heat shield bolts to 80 inch lbs.

Fig. 1 Engine coolant thermostat housing replacement

Fig. 2 Turbocharger heat shield replacement

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