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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 708 (Engine Mechanical - 2.4L (LE5)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2007 Pontiac G5 Pursuit, 2007 Pontiac G5, and 2007 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Caps Or Plugs, Fuel Line And Fuel Rail
    GM1647977Courtesy of GENERAL MOTORS CORP.
  1. Ensure that the tires are in the straight forward position. Remove the key from the ignition.
  2. Raise the hood.
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  5. Disconnect the fuel feed line quick connect fitting (4) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  6. Disconnect the evaporative emission (EVAP) line quick connect fitting (3) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Remove the fuel line clips (1, 2) from the engine brackets.
    8. Fig 2: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  8. Drain the cooling system. Refer to Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5)) .
  9. Secure the cooling module to the upper body structure.
  10. Remove the engine drive belt. Refer to Drive Belt Replacement .
    11. Fig 3: Identifying Cooling Fan Electrical Connector
    GM1647978Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the cooling fan electrical connector.
    12. Fig 4: View Of Radiator Inlet Hose To Engine
    GM1656126Courtesy of GENERAL MOTORS CORP.
  12. Reposition the radiator inlet hose clamp at the engine.
  13. Remove the radiator inlet hose from the engine.
    14. Fig 5: View Of Radiator Outlet Hose To Thermostat Housing
    GM1656115Courtesy of GENERAL MOTORS CORP.
  14. If the vehicle is equipped with a engine oil cooler perform the following steps, otherwise proceed to step 19.
  15. Reposition the radiator outlet hose clamp (1) at the water outlet.
  16. Reposition the radiator outlet hose clamp (2) at the oil cooler.
  17. Remove the radiator outlet hose from the water outlet.
  18. Remove the radiator outlet hose from the oil cooler. Proceed to step 23.
    19. Fig 6: View of surge tank outlet hose
    GM1713860Courtesy of GENERAL MOTORS CORP.
  19. If the vehicle is not equipped with a engine oil cooler, reposition the surge tank outlet hose clamp at the surge tank.
  20. Remove the surge tank outlet hose from the surge tank.
    21. Fig 7: Identifying Radiator Outlet Hose
    GM1649362Courtesy of GENERAL MOTORS CORP.
  21. Reposition the radiator outlet hose clamp (1) at the thermostat cover.
  22. Remove the radiator outlet hose from the thermostat cover.
    23. Fig 8: View Of Heater Inlet And Outlet Hoses And Thermostat Housing Pipes
    GM1656127Courtesy of GENERAL MOTORS CORP.
  23. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
  24. Remove the heater inlet (2) and outlet (1) hoses from the thermostat housing.
    25. Fig 9: View of Vacuum brake booster hose clamp
    GM1656109Courtesy of GENERAL MOTORS CORP.
  25. Reposition the brake booster vacuum hose clamp (2) at the intake manifold.
  26. Remove the brake booster vacuum hose from the intake manifold. Reposition the hose.
    27. Fig 10: Identifying Engine Harness Electrical Connector
    GM1647528Courtesy of GENERAL MOTORS CORP.
  27. Disconnect the following electrical connectors:
    • Throttle actuator control (TAC) (1)
    • Manifold absolute pressure (MAP) sensor
    • Fuel injector harness (2)
    • Generator (3)
    28. Fig 11: View of engine harness clip
    GM1656100Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the engine harness clip (2) from the oil level indicator tube.
  29. Disconnect the engine harness clips (1 and 3) from the intake manifold.
    30. Fig 12: Identifying Camshaft Position Actuator Solenoid Valve Electrical Connectors
    GM1647538Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the ignition coils electrical connectors (1).
  31. Disconnect the intake (3) and exhaust (2) camshaft position actuator electrical connectors.
    32. Fig 13: View of engine harness clips
    GM1656114Courtesy of GENERAL MOTORS CORP.
  32. Remove the engine harness clips (1 and 2) from the camshaft cover.
    33. Fig 14: View Of Battery Connections
    GM1656128Courtesy of GENERAL MOTORS CORP.
  33. Remove the negative battery cable ground nut (4).
  34. Remove the engine harness ground terminal (3) from the stud.
  35. Remove the negative battery cable ground terminal (2) from the stud.
    36. Fig 15: View Of Knock Sensor (KS) Electrical Connector
    GM1656089Courtesy of GENERAL MOTORS CORP.
  36. Disconnect the following engine harness electrical connectors:
    • Oil pressure sensor (2)
    • Crankshaft position (CKP) sensor (1)
    • Knock sensor (3)
    37. Fig 16: Locating EVAP Purge Solenoid Electrical Connector
    GM1647981Courtesy of GENERAL MOTORS CORP.
  37. Disconnect the EVAP purge solenoid electrical connector (2).
  38. Remove the engine harness clip (1) from the purge solenoid bracket.
    39. Fig 17: Identifying Engine Harness Ground Terminal
    GM1647996Courtesy of GENERAL MOTORS CORP.
  39. Remove the engine harness ground bolt.
  40. Reposition the engine harness ground terminal.
    41. Fig 18: View Of Engine Harness Electrical Connector To A/C Compressor And Pressure Switch
    GM1656130Courtesy of GENERAL MOTORS CORP.
  41. Disconnect the engine harness electrical connector (1) from the air conditioning (A/C) pressure switch.
  42. Disconnect the engine harness electrical connector (2) from A/C compressor.
  43. Unbolt and reposition the AC compressor aside.
  44. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  45. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
    46. Fig 19: Identifying Transaxle Fluid Cooler Lines & Bracket Nut
    GM1647991Courtesy of GENERAL MOTORS CORP.
  46. Remove the transaxle fluid cooler bracket nut.
  47. Remove the transaxle fluid cooler lines from the transaxle.
    48. Fig 20: Identifying Engine Harness Clips
    GM1647983Courtesy of GENERAL MOTORS CORP.
  48. Remove the engine harness clip nut (3) from the engine stud.
  49. Remove the engine harness clip (1) from the stud.
  50. If equipped with a automatic transaxle, disconnect the engine harness electrical connector (2) from the vehicle speed sensor (VSS).
  51. Remove the engine harness clip (3) from the speed sensor.
    52. Fig 21: View Of Negative Battery Cable
    GM1656131Courtesy of GENERAL MOTORS CORP.
  52. Remove the positive battery cable lead nut (5) from the starter solenoid.
  53. Remove the positive battery cable terminal (4) from the starter.
  54. Remove the engine harness terminal (3) from the starter.
  55. Remove the engine harness to starter solenoid "S" terminal nut (2).
  56. Remove the engine harness lead terminals (1) from the starter solenoid.
  57. Lower the vehicle.
    58. Fig 22: Identifying Engine Harness
    GM1647985Courtesy of GENERAL MOTORS CORP.
  58. If equipped with a automatic transaxle, disconnect the engine harness from the transaxle.
    59. Fig 23: Identifying Engine Harness Electrical Connectors - Top Of Engine
    GM1647986Courtesy of GENERAL MOTORS CORP.
  59. If equipped with a automatic transaxle, perform the following steps. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor.
  60. Remove the heated oxygen sensor (HO2S) connector position assurance (CPA) retainers.
  61. Disconnect the engine harness electrical connectors (2, 4) from the HO2S.
  62. Remove the HO2S connector clips from the thermostat housing and engine bracket.
  63. Disconnect the engine harness electrical connector (1) from the park neutral position switch.
    64. Fig 24: Identifying Engine Harness Electrical Connectors
    GM1648166Courtesy of GENERAL MOTORS CORP.
  64. If equipped with a manual transaxle, disconnect the engine harness electrical connector (6) from the VSS.
  65. Disconnect the engine harness electrical connector (7) from the back up lamp switch.
  66. Remove the HO2S CPA retainers (2, 4).
  67. Disconnect the engine harness electrical connectors (1, 5) from the HO2S.
  68. Remove the HO2S clips from the engine brackets.
  69. Gather all engine harness branches are reposition the harness off to the side, out of the way.
    70. Fig 25: Identifying Range Selector Level Cable
    GM1647987Courtesy of GENERAL MOTORS CORP.
  70. If equipped with a automatic transaxle, disconnect the range selector lever cable from the transaxle lever.
  71. Remove the range selector lever cable from the transaxle bracket.
    72. Fig 26: Range Selector And Shift Lever Cables
    GM1625583Courtesy of GENERAL MOTORS CORP.
  72. If equipped with a manual transaxle, disconnect the range selector and shift lever cables from the transaxle levers.
  73. Remove the range selector and shift lever cables from the transaxle bracket.
  74. Remove the catalytic converter. Refer to Catalytic Converter Replacement (RPO LE5) .
  75. Lower the vehicle.
  76. Insert blocks of wood between the powertrain and the frame, in order to support the powertrain.
  77. Remove the engine mount. Refer to Engine Mount Replacement .
    78. Fig 27: Identifying Transaxle Mount to Transaxle Bolts
    GM1647344Courtesy of GENERAL MOTORS CORP.
  78. Remove the transaxle mount to transaxle bolts.
  79. Raise the vehicle.
  80. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .
  81. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
  82. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement .
  83. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement .
    84. Fig 28: Identifying Engine Lift Hoist-To-Engine Lift Hooks
    GM1647988Courtesy of GENERAL MOTORS CORP.
  84. Using a paint pen or magic marker, mark the frame to body position.
  85. Lower the vehicle to about 3 feet off the ground.
  86. Position a engine lift table under the frame.
  87. Place wood blocks on top of the lift table between the table and the frame.
  88. Lower the vehicle until the frame is resting on the blocks of wood.
  89. Slowly loosen/remove the frame bolts using the following sequence:
    1. Loosen/remove the front frame bolts.
    2. Loosen/remove the rear frame bolts.
  90. Slowly raise the vehicle away from the powertrain assembly.
  91. Slide the lift table out from under the vehicle.
  92. Attach the engine lift hoist to the engine lift hooks.
    93. Fig 29: Identifying Starter Bolts & Starter
    GM1648192Courtesy of GENERAL MOTORS CORP.
  93. Remove the starter bolts and starter.
    94. Fig 30: Identifying Torque Converter Housing Access Plug
    GM1647989Courtesy of GENERAL MOTORS CORP.
  94. If equipped with a automatic transaxle, remove the torque converter housing access plug.
    95. Fig 31: Identifying Torque Converter Bolts
    GM1647992Courtesy of GENERAL MOTORS CORP.
  95. If equipped with a automatic transaxle, remove the torque converter bolts.
    96. Fig 32: View Of Transaxle Brace & Bolts
    GM1647995Courtesy of GENERAL MOTORS CORP.
  96. Remove the transaxle brace bolts and brace.
    97. Fig 33: Identifying Engine Bolts/Stud
    GM1647993Courtesy of GENERAL MOTORS CORP.
  97. If equipped with a manual transaxle, remove the transaxle to engine bolts/stud.
    98. Fig 34: Identifying Engine To/From Transaxle
    GM1647994Courtesy of GENERAL MOTORS CORP.
  98. If equipped with a automatic transaxle, remove the transaxle to engine bolts/stud.
  99. Separate the engine from the transaxle.
  100. If equipped with a manual transaxle, remove the clutch pressure plate and disc. Refer to Clutch Drive Plate and Clutch Driven Plate (M86) or Clutch Drive Plate and Clutch Driven Plate (MU3) .
  101. Remove the following components:
    • The engine mount bracket
    • The engine block heater
    • The generator
  102. Using a engine hoist, install the engine to a engine stand.
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