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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 31 (ENGINE MECHANICAL)REPAIR INSTRUCTIONSOFF-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 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. Remove the battery. Refer to Battery Replacement in Engine Electrical.
  2. Remove the intake air cleaner. Refer to Air Cleaner Assembly Replacement .
  3. Disconnect the MAF connector.
  4. Remove the battery ground cable at the wheel housing.
  5. Remove the positive main feed cable at the fuse block.
  6. Disconnect the TCM main connector under the cowl cover and secure to the engine.
  7. Disconnect the TCM inline connector located near the brake master cylinder.
  8. Disconnect the A/C pressure connector.
  9. Remove the fuse block.
    1. Remove the fuse block cover.
    2. Disconnect the BLACK engine harness connector under the fuse block panel.
    3. Remove the lower weather-pack connector inside the fuse block.
    4. Secure the engine harness to the top of the engine.
    5. Remove the fuse block mounting bolts.
    6. Remove the fuse block and secure away from the engine.
  10. Remove the battery tray.
  11. Disconnect the EVAP purge connector.
  12. Disconnect the right front speed sensor connector and secure to the top of the engine.
  13. Disconnect the front O2 sensor from down pipe.
  14. Disconnect the following electrical connections:
    1. The transaxle ground
    2. The transaxle main connector
    3. The transaxle shift control
    4. The rear connector on ECM
  15. Remove the brake booster vacuum hose.
  16. Relieve the fuel pressure.
  17. Disconnect the fuel lines and secure away from the engine.
  18. Disconnect the EVAP purge hose at the EVAP purge solenoid.
  19. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  20. Remove the starter.
  21. Remove the torque converter bolts.
  22. Drop the exhaust system from the catalytic converter forward.
  23. Disconnect the transaxle nose bracket.
  24. Remove the A/C compressor mounting bolts and secure to the frame rail.
  25. Drain the engine coolant.
  26. Disconnect the heater hoses at the lower cowl.
  27. Disconnect the lower engine to transaxle bell housing bolts. Do not remove the upper bolts at this time.
  28. Lower the vehicle.
  29. Remove the main hose to the coolant reservoir from the engine inlet adapter.
  30. Remove the lower radiator hose from the engine.
  31. Remove the upper radiator hose from the engine.
  32. Drain the power steering fluid by removing the small hose from under the reservoir.
  33. Disconnect the metal power steering line.
  34. Disconnect the power steering reservoir from the radiator support and secure to the top of the engine.
  35. Attach the engine lift hoist to the lift hooks on the engine and support the engine weight.
  36. Remove the right front engine mount from the wheel housing.
  37. Remove the engine mount bracket from the engine.
  38. Remove the upper bell housing bolts.
  39. Lift the engine out of the vehicle.
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.