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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 737 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions - On Vehicle >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
  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 inlet duct and resonator. Refer to Air Cleaner Outlet Resonator Replacement .
    4. Fig 1: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  4. Secure the cooling module to the upper body structure.
  5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) or Fuel Pressure Relief (With CH 48027) .
  6. Disconnect the fuel line from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  7. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill LE5, L61) .
  8. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LE5, L61) .
  9. Remove the surge tank to cylinder head hose. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (LE5, L61) and Radiator Surge Tank Outlet Hose/Pipe Replacement (LE5, L61) .
  10. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LE5, L61) .
    11. Fig 2: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  11. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Inlet Hose Replacement (L61, LE5) and HEATER OUTLET HOSE REPLACEMENT (L61, LE5) .
    12. Fig 3: View Of Engine Mount To Intermediate Bracket Bolts
    GM851553Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the following harness connectors:
    • Idle air control (IAC) motor
    • Temperature position sensor (TPS)
    • Manifold absolute pressure (MAP) sensor
    • Crankshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil and module assembly
    • Oxygen (O2) sensor
    • Vehicle speed sensor
    • Engine temperature sensor
    • Backup lamp switch
  13. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  14. Remove the engine drive belt. Refer to Drive Belt Replacement .
  15. Remove the A/C compressor bolts and set the compressor aside.
    16. Fig 4: Identifying Starter Electrical Connectors
    GM758469Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the starter harness connectors (3, 4, 5).
  17. Disconnect the generator harness connectors.
  18. Drain the engine oil.
  19. Disconnect the front exhaust pipe from the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT (L61) .
  20. Disconnect the transmission harness connectors.
  21. Disconnect the transmission shift cable from the transmission.
  22. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  23. Remove the engine mount. Refer to Engine Mount Replacement .
    24. Fig 5: View Of Side Transmission Mount
    GM851558Courtesy of GENERAL MOTORS CORP.
  24. Remove the side transmission mount. Refer to the appropriate procedure:
    25. Fig 6: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .
    26. Fig 7: View Of Tie Rod End & Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
    27. Fig 8: View Of Intermediate Shaft-To-Steering Gear Pinch Bolt
    GM851655Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.
  27. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement .
    28. Fig 9: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement .
    29. Fig 10: View Of Drive Axle & Steering Knuckle
    GM851677Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the drive axles from the steering knuckle. Refer to Wheel Drive Shaft Replacement .
  30. Use a paint pen or magic marker in order to mark the frame to body position.
  31. Lower the vehicle to about 1 m (3 ft) off the ground in order to position the lift table under the frame.
  32. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  33. Slowly remove the frame bolts using the following sequence:
    1. Remove the front frame bolts.
    2. Partially unscrew the rear frame bolts until 4 cm (1.5 in) of bolt shank is exposed.
  34. Slowly lower the table to the floor with the cradle and powertrain assembly.
  35. Attach the engine lift hoist to the engine lift hooks.
    36. Fig 11: View Of Starter
    GM758470Courtesy of GENERAL MOTORS CORP.
  36. Remove the starter.
  37. If applicable, remove the torque converter to flywheel bolts.
  38. Remove the transmission to engine bolts.
  39. Separate the engine from the transmission.
  40. If applicable, remove the clutch pressure plate and disk.
  41. Remove the following components:
    • Exhaust manifold
    • Exhaust manifold studs
    • Engine mount bracket
    • Engine block heater
    • Thermostat housing and feed pipe
    • Generator
  42. Remove the engine from the engine lift.
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