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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 31 (ENGINE MECHANICAL)REPAIR INSTRUCTIONSOFF-VEHICLE REPAIR INSTRUCTIONSENGINE REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2005 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing & Installing Engine Assembly
    GM896483Courtesy of GENERAL MOTORS CORP.
  1. Lower the engine into the vehicle and guide it to mate with the dowel pins on the transaxle.
  2. When the engine and the transaxle are aligned on the shuffle pins, install the upper bell housing bolts. Do not torque at this time.
  3. Install the engine mount bracket onto the engine and install the bolts.

    Tighten:  Tighten the engine mount bracket bolts to 55 N.m (41 lb ft).

  4. Install the right front engine mount and install the bolts.

    Tighten:  Tighten the engine mount-to-frame bolts to 55 N.m (41 lb ft).

  5. Install the transaxle nose bracket bolts.

    Tighten:  Tighten the nose cone bracket-to-oil pan bolts (transaxle nose bracket bolts) to 40 N.m (30 lb ft).

  6. Remove the engine lift hoist.
  7. Attach the metal power steering line.
  8. Attach the small hose to the bottom of the power steering reservoir.
  9. Attach the power steering reservoir to the radiator support.
  10. Install the upper radiator hose.
  11. Install the lower radiator hose
  12. Attach the main coolant reservoir hose to the engine.
  13. Raise the vehicle.
  14. Install the lower engine to the transaxle bell housing bolts and torque.

    Tighten:  Tighten the lower engine-to-transaxle bell housing bolts to 65 N.m (48 lb ft).

  15. Install the torque converter bolts.

    Tighten:  Tighten the torque converter bolts to 65 N.m (48 ft).

  16. Install the starter.
  17. Connect the heater hoses at the lower cowl.
  18. Install the A/C compressor to the engine mounting bracket.

    Tighten:  Tighten the A/C compressor bracket bolts to 40 N.m (30 lb ft).

  19. Install the exhaust down pipes to the catalytic converter.
  20. Lower the vehicle.
  21. Connect the EVAP purge solenoid hose.
  22. Connect the fuel lines.
  23. Connect the brake booster vacuum hose.
  24. Connect the following electrical connections:
    1. The rear connector on the ECM
    2. The transaxle shift control
    3. The transaxle main connector
    4. The transaxle ground
    5. The right front speed sensor
  25. Connect the front O2 sensor connector.
  26. Connect the right front speed sensor.
  27. Connect the EVAP purge solenoid connector.
  28. Torque the upper bell housing bolts.

    Tighten:  Tighten the upper bell housing bolts to 65 N.m (48 lb ft).

  29. Install the battery tray.
  30. Install the fuse block.
    1. Install the fuse block mounting bolts.
    2. Route the engine harness into the block.
    3. Connect the lower weather pack connector.
    4. Connect the main engine harness under the fuse block panel.
    5. Assemble the fuse block.
  31. Connect the A/C pressure connector.
  32. Connect the TCM inline connector near the brake master cylinder.
  33. Connect the TCM main connector under the cowl cover and secure it to the engine.
  34. Connect the positive main feed cable at the fuse block.
  35. Connect the battery ground cable at the wheel housing.
  36. Install the battery.
  37. Install the intake air cleaner. Air Cleaner Assembly Replacement
  38. Connect the MAF connector.
  39. Add coolant.
  40. Add power steering fluid.
  41. Start the engine and check for leaks.
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.