GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Cobalt 🢒 Engine 🢒 Engine Mechanical - 2.0L 🢒 Engine Replacement

Removal Procedure
  1. With the tires in the straight forward position, remove the key from the ignition.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Remove the air outlet duct . Refer to Air Cleaner Outlet Resonator Replacement .

    4. Object Number: 857193 Size: SH
  4. Secure the cooling module to the upper body structure.
  5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    6. Object Number: 1387192 Size: SH
  6. Disconnect the fuel line from the fuel rail.
  7. Drain the cooling system. Refer to Cooling System Draining and Filling .
  8. Remove the radiator inlet hose.
  9. Remove the surge tank to cylinder head pipe. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement and Radiator Surge Tank Outlet Hose/Pipe Replacement .
  10. Remove the radiator outlet hose.

    11. Object Number: 786506 Size: SH
  11. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .

    12. Object Number: 851553 Size: SH
  12. Disconnect the following harness connectors:
    13. • TMAP sensor
    • Electronic temperature control (ETC)
    • Manifold absolute pressure (MAP) sensor
    • Barometric pressure (BARO) sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil modules
    • Oxygen (O2) sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Boost solenoid
    • Back-up lamp switch
  13. Remove the engine drive belt. Refer to Drive Belt Replacement .
  14. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  15. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

    16. Object Number: 865182 Size: SH
  16. Disconnect the compressor and condenser hose assembly from the compressor.
  17. Remove the AC compressor bolts and set the compressor aside.

    18. Object Number: 758469 Size: SH
  18. Disconnect the starter harness connectors (3, 4, 5).
  19. Disconnect the generator harness connectors.
  20. Drain the engine oil.
  21. Disconnect the front exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Replacement .
  22. Disconnect the transmission shift cable from the transmission.
  23. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  24. Remove the engine mount. Refer to Engine Mount Replacement .

    25. Object Number: 851558 Size: SH
  25. Remove the left transmission mount. Refer to Transmission Mount Replacement - Left Side .

    26. Object Number: 851720 Size: SH
  26. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .

    27. Object Number: 854972 Size: SH
  27. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .

    28. Object Number: 851655 Size: SH

    Important: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

  28. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement .

    29. Object Number: 851659 Size: SH
  29. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement .

    30. Object Number: 851677 Size: SH
  30. Disconnect the drive axles from the steering knuckle. Refer to Wheel Drive Shaft Replacement .
  31. Use a paint pen or magic marker in order to mark the frame to body position.

    32. Object Number: 851651 Size: SH
  32. Lower the vehicle to about 1 meter (3 feet) off the ground in order to position the lift table under the frame.
  33. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  34. Slowly remove the frame bolts using the following sequence:
    35. 34.1. Remove the front frame bolts.
    34.2. Partially unscrew the rear frame bolts until 38 mm (1.5 in) of bolt shank is exposed.
  35. Slowly lower the table to the floor.
  36. Attach the engine lift hoist to the engine lift hooks.

    37. Object Number: 758470 Size: SH
  37. Remove the starter.
  38. Remove the transmission to engine bolts.
  39. Separate the engine from the transmission.
  40. Remove the clutch pressure plate and disk.
  41. Remove the following components:
    42. • The exhaust manifold
    • The exhaust manifold studs
    • The engine mount bracket
    • The fuel rail
    • The thermostat housing and feed pipe
    • The generator
  42. Remove the engine from the engine lift.

Installation Procedure
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the following components:
    3. • The exhaust manifold--Refer to Exhaust Manifold Replacement .
    • The fuel rail--Refer to Fuel Injection Fuel Rail Assembly Replacement .
    • The idler pulley
    • The drive belt tensioner--Refer to Drive Belt Tensioner Replacement - Supercharger .
    • The thermostat housing and feed pipe--Refer to Engine Coolant Thermostat Replacement .
    • The generator--Refer to Generator Replacement .
    • 
    • The flywheel--Refer to Engine Flywheel Replacement .
    • The clutch pressure plate and disk--Refer to Clutch Pressure and Driven Plate Replacement .
    • The AC compressor--Refer to Air Conditioning Compressor Replacement .
    • 
  3. Align the engine to the transmission.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 851293 Size: SH

    Important: The number 3 bolt location is not used.

  4. Secure the engine to the transmission.

    5. Tighten
    Tighten the transmission to engine bolts to 75 N·m (55 lb ft).


    Object Number: 758470 Size: SH
  5. Install the starter. Refer to Starter Motor Replacement .
  6. Remove the engine lift from the engine.

    7. Object Number: 851651 Size: SH
  7. Raise and position the frame and powertrain assembly to the vehicle.
  8. Hand start all the frame bolts while aligning the frame to the paint marks.
  9. Tighten the frame bolts.

    10. Tighten
    Tighten the frame bolts to 100 N·m (74 lb ft) plus 180 degrees.

  10. Remove the lift table.

    11. Object Number: 851677 Size: SH
  11. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement .

    12. Object Number: 851659 Size: SH
  12. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .

    13. Object Number: 851655 Size: SH
  13. Connect the intermediate steering shaft to the steering gear. Refer to Steering Gear Replacement .

    14. Object Number: 854972 Size: SH
  14. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .

    15. Object Number: 851720 Size: SH
  15. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .

    16. Object Number: 851558 Size: SH
  16. Install the left transmission mount. Refer to Transmission Mount Replacement - Left Side .

    17. Object Number: 851553 Size: SH
  17. Install the engine mount. Refer to Engine Mount Replacement .
  18. Remove the wood blocks between the powertrain and frame.
  19. Connect the transmission shift cable to the transmission.

    20. Object Number: 878834 Size: SH
  20. Connect the exhaust takedown pipe to the exhaust manifold.

    21. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).

  21. Connect the generator harness connectors.

    22. Tighten
    Tighten the generator terminal nut to 20 N·m (15 lb ft).


    Object Number: 758469 Size: SH
  22. Connect the starter harness connectors (3, 4, 5).

    23. Tighten

        • Tighten the battery terminal nut to 17 N·m (13 lb ft).
        • Tighten the S-terminal nut to 3 N·m (27 lb in).
  23. Install the compressor and condenser hose assembly to the compressor. Refer to Compressor Hose Assembly Replacement .
  24. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  25. Install the engine drive belt. Refer to Drive Belt Replacement .
  26. Connect the following harness connectors:
    27. • TMAP sensor
    • ETC
    • MAP sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • BARO sensor
    • Ignition coil modules
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Boost solenoid

    Object Number: 786506 Size: SH
  27. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
  28. Install the radiator outlet hose. Refer to Radiator Inlet Hose Replacement .

    29. Object Number: 1387192 Size: SH
  29. Connect the fuel line to the fuel rail.
  30. Install the surge tank to the cylinder head pipe.

    31. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 857193 Size: SH
  31. Release the cooling module from the upper body structure.
  32. Install the air outlet duct . Refer to Air Cleaner Outlet Resonator Replacement .
  33. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  34. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations .
  35. Fill the cooling system. Refer to Cooling System Draining and Filling .
  36. Road test the vehicle.