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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 428 (ENGINE MECHANICAL - 2.2L (L61))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 2006 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  2. Disconnect the air intake temperature (IAT) sensor connector.
  3. Loosen the clamp air cleaner assembly.
  4. Remove the pushpin attachment from the outlet resonator/duct assembly to the support bracket.
  5. Loosen the clamp at the throttle body assembly.
  6. Disconnect the positive crankcase ventilation (PCV) fresh air vent hose at the cam cover.
  7. Remove the outlet resonator/duct assembly.
    8. Fig 2: View Of Shop Towel Over The Throttle Body Opening
    GM897640Courtesy of GENERAL MOTORS CORP.
  8. Cover the throttle body opening with a shop towel. Use shop air to remove any dirt around the throttle body and intake manifold to cylinder head.
    9. Fig 3: View Of Underhood Fuse Block (UHFB)
    GM934982Courtesy of GENERAL MOTORS CORP.
  9. Remove the underhood fuse block (UHFB) fuse cover by separating the clips on each side.
  10. Remove the UHFB fuse cover.
  11. Remove the inner UHFB fuse cover.
  12. Loosen the three connectors through bolts (1) at the top of the UHFB.
  13. Remove the battery and the electronic power steering feed wire connection nut and remove the wire from the UHFB stud.
  14. Release the tabs on each side of the UHFB with a screwdriver.
  15. Raise the UHFB from the connectors. Disconnect the electrical connectors on each side of UHFB.
  16. Remove the UHFB from the vehicle.
  17. Remove the battery cable and the harness attachment clips the on side of battery tray/UHFB bracket assembly.
  18. Remove the main connectors from the UHFB housing.
  19. Lay the battery positive cable wire over the engine. The battery cables will be removed with powertrain assembly.
  20. Remove the electrical harness clips to battery tray.
  21. Remove the UHFB and the battery tray bolts.
  22. Remove the UHFB and the battery tray.
    23. Fig 4: View Of Battery Tray Bracket Bolts
    GM951487Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the electrical connectors at the transaxle control module (TCM), if equipped.
  24. Remove the engine-to-body ground bolt.
  25. Disconnect the connector for the rear O2 sensor.
  26. Remove the vacuum hose with the check valve from the booster and lay across the engine.
  27. Disconnect the 8-way electrical connector.
  28. Remove the main engine harness gray connector and lay over the engine assembly. This will allow the engine harness to be removed the with powertrain.
    29. NOTE: Do not remove the shifter cable from the bracket before removing the cable from the transaxle range switch. Damage to the manual shift linkage may occur.
  29. If equipped with the automatic range transaxle, disconnect the shifter cable plastic retainer by using a screwdriver. Slightly pry between the shifter cable plastic retainer and the transaxle range switch.
    30. Fig 5: Locating Shift Level Cables
    GM982570Courtesy of GENERAL MOTORS CORP.
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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.