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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 103 (ENGINE MECHANICAL - 3.8L)REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSENGINE REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Removal Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Removal Procedure
WARNING: This page is about a different car, the 2005 Buick LaCrosse and 2005 Buick Allure. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Remove the hood. Refer to Hood, Hinge, Rod, Stud Replacement - Hood in Body Front End.
  3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  6. Drain the cooling system. Refer to Draining and Filling Cooling System (LY7) or Draining and Filling Cooling System (L26) in Engine Cooling.
  7. Remove the torque converter covers. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
    8. Fig 1: View Of Engine Electrical Connectors (Left Side)
    GM911140Courtesy of GENERAL MOTORS CORP.
  8. Remove the engine ground nut (5) and the engine ground wire (6) from the transaxle stud.
  9. Remove the oil level sensor harness retainer bolt.
  10. Remove the oil level harness retainer from the engine.
  11. Disconnect and reposition the electrical connectors from the following components:
    • Vehicle speed sensor (VSS)
    • Oil pressure sensor
    • Oil level sensor (10)
    • Knock sensors
    • Heated oxygen sensor (H02S)
  12. Remove the starter motor. Refer to Starter Motor Replacement (LY7) or Starter Motor Replacement (L26) in Engine Electrical.
  13. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
  14. Scribe the torque converter to the flywheel for installation.
  15. Remove the transaxle brace. Refer to Automatic Transmission Brace Replacement in Automatic Transaxle - 4T65-E.
  16. Remove the engine mount lower nuts.
    17. Fig 2: Right Exhaust Manifold & Catalytic Converter Pipe
    GM911163Courtesy of GENERAL MOTORS CORP.
  17. Remove the exhaust manifold pipe stud nuts (2) and reposition the catalytic converter from the exhaust manifold.
  18. Remove the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
    19. Fig 3: View of Transaxle To Engine Mounting
    GM160965Courtesy of GENERAL MOTORS CORP.
  19. Remove the lower transaxle to the engine bolt (6) and the stud (1).
  20. Lower the vehicle while supporting the transaxle.
  21. Remove the air cleaner assembly. Refer to Air Cleaner Element Replacement in Engine Controls - 3.8L.
  22. Disconnect the fuel line from the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 3.8L.
  23. Disconnect the fuel vapor line. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Engine Controls - 3.8L.
    24. Fig 4: View Of Water Pump Pulley And Bolts
    GM46174Courtesy of GENERAL MOTORS CORP.
  24. Loosen the water pump pulley bolts.
  25. Remove the drive belt. Refer to Drive Belt Replacement (L26) .
  26. Remove the water pump pulley bolts and the water pump pulley.
  27. Remove the right and the left engine mount struts. Refer to Engine Mount Strut Replacement - Right  and Engine Mount Strut Replacement - Left .
  28. Remove the engine mount brackets from the radiator support. Refer to Engine Mount Bracket Replacement - Front .
  29. Disconnect the positive battery cable.
  30. Remove the engine cooling fans. Refer to Cooling Fan Motor Replacement - Electric (L26) or Cooling Fan Motor Replacement - Electric (LY7) in Engine Cooling.
  31. Remove the vacuum booster hose from the engine. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement in Hydraulic Brakes.
  32. Disconnect the A/C vacuum hose from the engine.
    33. Fig 5: View Of Power Steering Pump And Mounting Bolts
    GM282122Courtesy of GENERAL MOTORS CORP.
  33. Remove the power steering pump bolts and pump from the engine. Lay the power steering pump aside.
  34. Disconnect the upper engine electrical connectors from the following components:
    • Electronic throttle control (ETC)
    • Fuel injectors
    • EVAP purge solenoid
    • Exhaust gas recirculation (EGR) valve
    • Manifold absolute pressure (MAP) sensor
    • BARO sensor, if equipped
    35. IMPORTANT: Note the position of the engine wiring harness during removal.
  35. Remove upper engine wiring harness from the retaining clips and reposition the engine wiring harness for engine removal.
  36. Remove the radiator inlet hose from the engine. Refer to Radiator Hose Replacement - Inlet (3.8L) or Radiator Hose Replacement - Inlet (3.6L) in Engine Cooling.
  37. Remove the radiator outlet hose from the engine. Refer to Radiator Hose Replacement - Outlet (3.8L) or Radiator Hose Replacement - Outlet (3.6L) in Engine Cooling.
  38. Remove the heater hoses from the drive belt tensioner. Refer to Heater Hose Replacement - Inlet (L26) and to Heater Hose Replacement - Outlet (L26) in Heating, Ventilation and Air Conditioning.
  39. Remove the A/C compressor from the engine. Refer to Compressor Replacement (L26) or Compressor Replacement (LY7) in Heating, Ventilation and Air Conditioning. DO NOT discharge the A/C system. Secure the compressor to the frame.
  40. Install the engine lifting device.
    41. Fig 6: View of Transaxle To Engine Mounting
    GM160965Courtesy of GENERAL MOTORS CORP.
  41. Remove the upper transaxle to the engine bolts (2, 3, 4, 5).
  42. With the aid of an assistant, remove the engine from the vehicle.
  43. Remove the flywheel. Refer to Engine Flywheel Replacement .
  44. Install the engine to the engine stand.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.