Friday, October 14, 2011

How to remove Engine on 2006 Chevrolet Cobalt?


Engine


Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the tires in the straight forward position, remove the key from the ignition.
  3. Disconnect the negative battery cable.
  4. Remove the air outlet duct.
  5. Secure the cooling module to the upper body structure.
  6. Relieve the fuel system pressure.
  7. Disconnect the fuel line from the fuel rail.
  8. Drain the cooling system.
  9. Remove the radiator inlet hose.
  10. Remove the surge tank to cylinder head pipe.
  11. Remove the radiator outlet hose.
  12. Remove the inlet and outlet heater hoses.
  13. Disconnect the following harness connectors:

    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 (O 2 ) sensor
    Vehicle speed sensor
    Engine temperature sensor
    Boost solenoid
    Back-up lamp switch
  14. Remove the accessory drive belt.
  15. Raise and suitably support the vehicle.
  16. Recover the refrigerant.
  17. Remove the right front fender liner.
  18. Disconnect the electrical connector from the compressor.
  19. Remove the compressor hose from the evaporator hose.
  20. Remove and discard the seal washer.
  21. Remove the lower right radiator mount.
  22. Remove the cap from the charge air cooler reservoir.
  23. Place a drain pan under the charge air cooler radiator.
  24. Reposition the inlet hose clamp at the auxiliary water pump.
  25. Remove the inlet hose from the auxiliary water pump and allow the cooling system to drain.
  26. Remove the auxiliary intercooler pump.
  27. Remove the mounting cover from the charge air cooler pump and position the pump forward.
  28. Disconnect the electrical connector from the pressure transducer.
  29. Remove the compressor and condenser hose assembly bolt from the compressor.
  30. Remove the compressor and condenser hose assembly from the compressor.
  31. Remove and discard the sealing washers.
  32. Remove the compressor hose from the condenser.
  33. Remove and discard the seal washer.
  34. Remove the auxiliary intercooler pump bolts and position the pump toward the driver-s side of the vehicle.
  35. Remove the compressor mounting bolts.
  36. Remove the compressor.
  37. Disconnect the starter harness connectors.
  38. Disconnect the generator harness connectors.
  39. Drain the engine oil.
  40. Disconnect the front exhaust pipe from the exhaust manifold.
  41. Disconnect the transaxle shift cable from the transaxle.
  42. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  43. Support the engine with a hydraulic floor jack. Use a piece of wood between the jack and the oil pan.
  44. Remove the engine mount to intermediate bracket bolts.
  45. Remove the engine mount to mid-rail nuts.
  46. Remove the engine mount from the engine compartment.

    Click image to see an enlarged view
    Fig. Underhood electrical center
  47. Remove the cover from the underhood electrical center.
  48. Remove the underhood positive battery terminal lug.
    WARNING
    Take note of the positioning of the positive battery cables before disconnecting the cables.
  49. Disconnect the positive battery cables from the underhood electrical center.
    WARNING
    The underhood electrical center bolts are retained in the electrical center.
  50. Loosen all of the underhood electrical bolts.
  51. Remove the underhood electrical center bracket from the vehicle and reposition the electrical center.
  52. Support the transaxle with a floor jack. Use a piece of wood between the jack and the transaxle.
  53. Remove the transaxle mount-to-transaxle bracket bolts.
  54. Remove the transaxle mount to mid-rail bolts.
  55. Using a floor jack, slowly lower the transaxle enough to remove the transaxle mount from the vehicle.
  56. Disconnect the control links from the stabilizer bar.
  57. Disconnect the outer tie rod ends from the steering knuckles.
    WARNING
    In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.
  58. Disconnect the intermediate shaft from the steering gear.
  59. Disconnect the lower control arms from the steering knuckles.
  60. Disconnect the halfshafts from the steering knuckle.
  61. Use a paint pen or magic marker in order to mark the frame to body position.
  62. Lower the vehicle to about 3 feet (1 meter) off the ground in order to position the lift table under the frame.
  63. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  64. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2. Partially unscrew the rear frame bolts until 1 1 / 4 inches (38mm) of bolt shank is exposed.
  65. Slowly lower the table to the floor.
  66. Attach the engine lift hoist to the engine lift hooks.
  67. Remove the starter.
  68. Remove the transaxle to engine bolts.
  69. Separate the engine from the transaxle.
  70. Remove the clutch pressure plate and disk.
  71. Remove the exhaust manifold
  72. Remove the exhaust manifold studs
  73. Remove the engine mount bracket
  74. Remove the fuel rail
  75. Remove the thermostat housing and feed pipe
  76. Remove the generator
  77. Remove the engine from the engine lift.
To install:
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the exhaust manifold
  3. Install the fuel rail
  4. Install the idler pulley
  5. Install the drive belt tensioner
  6. Install the thermostat housing and feed pipe. Install the thermostat housing cap bolts and cap. Tighten the bolt to 18 inch lbs. (10 Nm).
  7. Install the generator
  8. Install the flywheel. Install the flywheel bolts. Tighten the flywheel bolts to 39 ft. lbs. (53 Nm) plus 25°.
  9. Install the clutch pressure plate and disk.
    WARNING
    NEW CVC compressor assemblies are shipped with a partial Poly-Alkylene Glycol (PAG) refrigerant oil charge. Use of the incorrect PAG oil can result in compressor failure.
  10. Install the compressor and the bolts to the engine. Tighten the bolts to 18 ft. lbs. (25 Nm).
  11. Install new sealing washers on the hose fittings.
  12. Install the hose assembly to the compressor.
  13. Install the assembly bolt. Tighten the bolt to 15 ft. lbs. (20 Nm).
  14. Connect the compressor electrical connector.
  15. Install the auxiliary intercooler pump. Tighten the pump bolt to 88 inch lbs. (10 Nm).
  16. Install the front fender liner.
  17. Align the engine to the transaxle.
    WARNING
    The number 3 bolt location is not used.



    Click image to see an enlarged view
    Fig. Transmission to engine bolts. The number 3 bolt location is not used
  18. Secure the engine to the transaxle. Tighten the transaxle to engine bolts to 55 ft. lbs. (75 Nm).
  19. Install the starter.
  20. Remove the engine lift from the engine.
  21. Raise and position the frame and powertrain assembly to the vehicle.
  22. Hand start all the frame bolts while aligning the frame to the paint marks.
  23. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus 180°.
  24. Remove the lift table.
  25. Connect the halfshafts to the steering knuckles.
  26. Connect the lower control arm to the steering knuckle.
  27. Connect the intermediate steering shaft to the steering gear.
  28. Connect the outer tie rod ends to the steering knuckles.
  29. Connect the control links to the stabilizer bar.
  30. Install the transaxle mount to the mid-rail.
  31. Install the transaxle mount to mid-rail bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
  32. Using a floor jack, raise the transaxle until it contacts the transaxle mount.
    WARNING
    The transaxle mount to transaxle bolts must be hand started. Do not pry the transaxle or mount to align the holes.
  33. Hand start the transaxle mount to bracket bolts using the following sequence:
    1. Rear bolt
    2. Middle bolt
    3. Front bolt
  34. Using the previous sequence, tighten the transaxle mount bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  35. Install the underhood electrical center bracket to the vehicle and install the electrical center into position on the bracket.
  36. Place the engine mount onto the mid-rail and hand start the nuts.
  37. Tighten the engine mount to mid-rail nuts. Tighten the nuts to 74 ft. lbs. (100 Nm).
    WARNING
    The engine mount to intermediate bracket bolts must be hand started. Do not pry the engine mount to align the holes.
  38. Hand start the engine mount to intermediate bracket bolts.
    WARNING
    The engine mount bracket bolts must be tightened in a mandatory torque sequence as shown.



    Click image to see an enlarged view
    Fig. Engine mount bracket bolt torque sequence
  39. Tighten the engine mount to intermediate bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  40. Remove the wood blocks between the powertrain and frame.
  41. Connect the transaxle shift cable to the transaxle.
  42. Connect the exhaust takedown pipe to the exhaust manifold. Tighten the nuts to 22 ft. lbs. (30 Nm).
  43. Connect the generator harness connectors. Tighten the generator terminal nut to 15 ft. lbs. (20 Nm).
  44. Connect the starter harness connectors. Tighten the battery terminal nut to 13 ft. lbs. (17 Nm). Tighten the S-terminal nut to 27 inch lbs. (3 Nm).
  45. Install the compressor and condenser hose assembly to the compressor.
  46. Evacuate and charge the refrigerant system.
  47. Install the accessory drive belt.
  48. Connect the following harness connectors:

    TMAP sensor
    ETC
    MAP sensor
    Crankshaft sensor
    Oil pressure sensor
    Purge solenoid
    BARO sensor
    Ignition coil modules
    2 sensor
    Vehicle speed sensor
    Engine temperature sensor
    Boost solenoid
  49. Install the inlet heater hose and outlet heater hose.
  50. Install the radiator outlet hose.
  51. Connect the fuel line to the fuel rail.
  52. Install the surge tank to the cylinder head pipe. Tighten the bolt to 89 inch lbs. (10 Nm).
  53. Release the cooling module from the upper body structure.
  54. Install the air outlet duct.
  55. Connect the negative battery cable.
  56. Fill the engine with engine oil to the proper level.
  57. Fill the cooling system.
  58. To fill the intercooler system:
    WARNING
    The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.

    1. Install the inlet hose to the auxiliary water pump.
    2. Reposition the inlet hose clamp to secure the hose.
    3. Lower the vehicle.
    4. Remove the right front headlamp assembly.
    5. Remove the bleeder screw from the radiator on the passenger top side of the charge air cooler.
      WARNING
      Use a 50/50 mixture of DEX-COOL® antifreeze and clean, drinkable water. It is necessary to maintain the coolant level near the cold fill line on the surge tank to ensure all the air has been purged from the cooling system.
    6. Slowly add a mixture of 50/50 DEX-COOL® antifreeze and clean, drinkable water to the cooling system until the coolant level reaches the top of the bleeder screw opening.
    7. Install the bleeder screw.
    8. Slowly add a mixture of 50/50 DEX-COOL® antifreeze and clean, drinkable water to the cooling system until the coolant level is just visible in the bottom of the charge air cooler reservoir. The coolant level will reach the hot fill line once the system has reached operating temperature.
    9. Install the cap to the charge air cooler reservoir.
    10. Inspect the cooling system for leaks.
    11. Install the right front headlamp assembly.
    12. Rinse away any excess coolant from the engine and the engine compartment.
  59. Road test the vehicle.


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