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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 499 (ENGINE MECHANICAL - 3.5L)REPAIR INSTRUCTIONSON-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 2007 Chevrolet Monte Carlo and 2007 Chevrolet Impala. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Transaxle-To-Engine Bolts/Studs
    GM1612980Courtesy of GENERAL MOTORS CORP.
  1. Install a engine lifting devise to the engine.
  2. Remove the engine from the engine stand.
  3. Install the flywheel. Refer to Engine Flywheel Installation (Automatic Transmission)  or Engine Flywheel Installation (Manual Transmission) .
  4. Install the engine to the vehicle.
    5. NOTE: Refer to Fastener Notice .
  5. Install the transaxle-to-engine bolts/studs.

    Tighten:  Tighten the bolts/stud to 75 N.m (55 lb ft).

    6. Fig 2: Power Steering Pump & Bolts
    GM1613157Courtesy of GENERAL MOTORS CORP.
  6. Remove the engine lifting device from the engine.
  7. Position and install the power steering pump bolts. Refer to Power Steering Pump Replacement (LZ4/LZE/LZ9) .
    8. Fig 3: View Of Radiator Inlet Hose & Crossover Pipe
    GM1613132Courtesy of GENERAL MOTORS CORP.
  8. Install the radiator inlet hose to the engine.
  9. Position the radiator inlet hose clamp at the engine.
    10. Fig 4: Position Heater Inlet & Outlet Hose/Pipe
    GM1608325Courtesy of GENERAL MOTORS CORP.
  10. Connect the EVAP purge line to the canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Connect the fuel feed line to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  12. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement (RPOs LZE/LZ4/LZ8) .
  13. Install the heater inlet and outlet hoses to the engine pipes.
  14. Position the heater inlet and outlet hose clamps at the engine.
    15. Fig 5: View Of Brake Booster Vacuum Hose & Intake Manifold
    GM1608820Courtesy of GENERAL MOTORS CORP.
  15. Install the brake booster vacuum hose to the intake manifold.
    16. Fig 6: Identifying Radiator Outlet Hose Clamp & Thermostat Housing
    GM1613134Courtesy of GENERAL MOTORS CORP.
  16. Install the radiator outlet hose to the thermostat housing.
  17. Position the radiator outlet hose clamp at the thermostat housing.
  18. Raise and support the vehicle.
    19. Fig 7: View Of Transaxle-To-Engine Lower Rear Bolt
    GM1613156Courtesy of GENERAL MOTORS CORP.
  19. Install the transaxle-to-engine lower rear bolt.

    Tighten:  Tighten the bolt to 75 N.m (55 lb ft).

    20. Fig 8: Locating Rear Transaxle Brace To Engine/Oil Pan Bolts
    GM1609665Courtesy of GENERAL MOTORS CORP.
  20. Install the transaxle brace.
  21. Install the transaxle brace to engine bolts.
  22. Install the transaxle brace to transaxle bolts.

    Tighten:  Tighten the bolts to 63 N.m (46 lb ft).

    23. Fig 9: View Of Air Conditioning (A/C) Compressor Front Bolt/Nut
    GM1608216Courtesy of GENERAL MOTORS CORP.
  23. Position the A/C compressor and install the compressor front bolt and nut.

    Tighten:  Tighten the bolt/nut to 50 N.m (37 lb ft).

    24. Fig 10: Locating A/C Compressor Rear Bolt
    GM1608220Courtesy of GENERAL MOTORS CORP.
  24. Install the A/C compressor rear bolt.

    Tighten:  Tighten the bolt to 50 N.m (37 lb ft).

    25. Fig 11: Locating Torque Converter Bolts
    GM1612979Courtesy of GENERAL MOTORS CORP.
  25. Install the torque converter bolts.

    Tighten:  Tighten the bolts to 63 N.m (46 lb ft).

  26. Install the starter motor. Refer to Starter Motor Replacement (RPOs LZE/LZ4/LZ9) .
  27. Install the torque converter cover. Refer to Torque Converter Cover Replacement .
    28. Fig 12: View Of Engine Mount Lower Nuts
    GM1607922Courtesy of GENERAL MOTORS CORP.
  28. Install the engine mount lower nuts.

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft).

    29. Fig 13: View Of Engine Harness Ground Bolt
    GM1612887Courtesy of GENERAL MOTORS CORP.
  29. Install the catalytic converter. Refer to Catalytic Converter Replacement (RPOs LZE/LZ4/LZ8) .
  30. Position the engine harness over the engine.
  31. Position the engine harness ground terminals (1) to the transmission.
  32. Install the engine harness ground bolt (2).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  33. Install the engine harness clip bolt (3) to the transmission.
    34. Fig 14: Identifying Knock Sensor Electrical Connector
    GM1612884Courtesy of GENERAL MOTORS CORP.
  34. Connect the CKP sensor electrical connector (4).
  35. Connect the knock sensor electrical connector (1).
  36. Install the engine harness clips (2, 3) to the transaxle brace.
  37. Lower the vehicle.
    38. Fig 15: Identifying The HO2S Electrical Connector
    GM1609170Courtesy of GENERAL MOTORS CORP.
  38. Connect the rear upper HO2S electrical connector (2).
  39. Install the CPA retainer (3).
    40. Fig 16: Locating Camshaft Position Actuator Magnet Electrical Connector
    GM1611455Courtesy of GENERAL MOTORS CORP.
  40. Install the engine harness clip (4) to the transaxle bracket.
  41. Install the engine harness clip bolt (3).

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  42. Connect the camshaft phasor sensor electrical connector (2).
    43. Fig 17: Identifying Engine Harness Clip (2) & Strut Bracket
    GM1608276Courtesy of GENERAL MOTORS CORP.
  43. Connect the fuel injector inline (1) electrical connector.
  44. Install the engine harness clips (2, 3) to the brackets.
    45. Fig 18: View Of MAP Sensor Electrical Connector
    GM1608869Courtesy of GENERAL MOTORS CORP.
  45. Connect the ignition coil electrical connector (6).
  46. Connect the generator electrical connector (3).
  47. Install the generator terminal (4).
  48. Install the generator terminal nut (5).

    Tighten:  Tighten the nut to 30 N.m (22 lb ft).

  49. Position the generator terminal boot (2).
  50. Connect the MAP sensor electrical connector (1).
    51. Fig 19: View Of EVAP Canister Purge Solenoid Electrical Connector
    GM1608290Courtesy of GENERAL MOTORS CORP.
  51. Connect the ETC (2) electrical connector.
  52. Connect the EVAP canister purge solenoid (1) electrical connector.
    53. Fig 20: Locating Engine Oil Level Sensor Electrical Connector
    GM1609295Courtesy of GENERAL MOTORS CORP.
  53. Raise the vehicle.
  54. Connect the oil level sensor electrical connector.
  55. Install the engine harness clips to the transaxle brace and the oil pan.
    56. Fig 21: Identifying Starter Motor Electrical Connector
    GM1608498Courtesy of GENERAL MOTORS CORP.
  56. Connect the A/C compressor electrical connector (4).
  57. Connect the starter motor electrical connector (3)
  58. Connect the knock sensor (2) electrical connector.
  59. Connect the oil pressure sensor (1) electrical connector.
    60. Fig 22: Locating Oil Pressure Sensor Heat Shield & Nut
    GM1609656Courtesy of GENERAL MOTORS CORP.
  60. Install the oil pressure sensor heat shield and nuts.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

  61. Lower the vehicle.
  62. Install the engine mount struts. Refer to Engine Mount Strut Replacement .
  63. Install the drive belt. Refer to Drive Belt Replacement .
  64. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  65. Install the hood. Refer to Hood Replacement .
  66. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  67. Fill the cooling system. Refer to Draining and Filling Cooling System (LZE, LZ4, LZ8, 9C1, 9C3, GE47716 Fill) or Draining and Filling Cooling System (LZE, LZ4, LZ8 Static Fill) .
  68. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  69. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (RPOs LZE/LZ4/LZ9) .
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.