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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Mechanical - 2.4L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying Engine To/From Transaxle
    GM1647994Courtesy of GENERAL MOTORS CORP.
  1. Using a engine hoist, remove the engine from the engine stand.
  2. Install the following components:
    • The engine mount bracket
    • The engine block heater
    • The generator
  3. If equipped with a manual transaxle, install 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) .
  4. Install the engine to the transaxle.
    5. NOTE: Refer to Fastener Notice .
  5. If equipped with a automatic transaxle, install the transaxle to engine bolts/stud.

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

    6. Fig 2: Identifying transaxle to engine Bolts/Stud (manual)
    GM1647993Courtesy of GENERAL MOTORS CORP.
  6. If equipped with a manual transaxle, install the transaxle to engine bolts/stud.

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

    7. Fig 3: View Of Transaxle Brace & Bolts
    GM1647995Courtesy of GENERAL MOTORS CORP.
  7. Install the transaxle brace and bolts.

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

    8. Fig 4: Identifying Torque Converter Bolts
    GM1647992Courtesy of GENERAL MOTORS CORP.
  8. If equipped with a automatic transaxle, install the torque converter bolts.

    Tighten:  Tighten the bolts to 62 N.m (46 lb ft).

    9. Fig 5: Identifying Torque Converter Housing Access Plug
    GM1647989Courtesy of GENERAL MOTORS CORP.
  9. If equipped with a automatic transaxle, install the torque converter housing access plug.
    10. Fig 6: Identifying Transaxle Fluid Cooler Lines & Bracket Nut
    GM1647991Courtesy of GENERAL MOTORS CORP.
  10. Install the transaxle fluid cooler lines to the transaxle.
  11. Install the transaxle fluid cooler bracket nut.

    Tighten:  Tighten the nut to 7 N.m (62 lb in).

    12. Fig 7: Identifying Starter
    GM1648192Courtesy of GENERAL MOTORS CORP.
  12. Install the starter and bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    13. Fig 8: Identifying Engine Lift Hoist-To-Engine Lift Hooks
    GM1647988Courtesy of GENERAL MOTORS CORP.
  13. Remove the engine lift hoist from the engine lift hooks.
  14. Slide the lift table under the vehicle.
  15. Slowly lower the vehicle until it aligns with the alignment marks made during the removal.
  16. Tighten/install the frame bolts.

    Tighten:  Tighten the bolts to 100 N.m (74 lb ft) plus and additional 180 degrees.

  17. Raise the vehicle until the lift table can be removed from under the vehicle.
  18. Remove the lift table.
    19. Fig 9: Identifying Transaxle Mount to Transaxle Bolts
    GM1647344Courtesy of GENERAL MOTORS CORP.
  19. Connect the lower control arms to the steering knuckles. Refer to Lower Control Arm Replacement .
  20. Connect the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement .
  21. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
  22. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .
  23. Lower the vehicle.
  24. Install the transaxle mount to transaxle bolts.

    Tighten:  Tighten the bolts to 45 N.m (33 lb ft).

    25. Fig 10: Range Selector And Shift Lever Cables
    GM1625583Courtesy of GENERAL MOTORS CORP.
  25. Install the engine mount. Refer to Engine Mount Replacement .
  26. Install the catalytic converter. Refer to Catalytic Converter Replacement (RPO LE5) .
    27. IMPORTANT: Ensure that the black cable is installed in the top notch of the transaxle bracket and the white cable in installed in the bottom notch of the transaxle bracket.
  27. If equipped with a manual transaxle, install the range selector and shift lever cables to the transaxle bracket.
  28. Connect the range selector and shift lever cables to the transaxle levers.
    29. Fig 11: Identifying Range Selector Level Cable
    GM1647987Courtesy of GENERAL MOTORS CORP.
  29. If equipped with a automatic transaxle, install the range selector lever cable to the transaxle bracket.
  30. Connect the range selector lever cable to the transaxle lever.
    31. Fig 12: Identifying Engine Harness Electrical Connectors
    GM1648166Courtesy of GENERAL MOTORS CORP.
  31. Gather all engine harness branches and position the harness over the engine.
  32. If equipped with a manual transaxle perform the following steps, install the HO2S clips to the engine brackets.
  33. Connect the engine harness electrical connectors (1, 5) to the HO2S.
  34. Install the HO2S CPA retainers (2, 4).
  35. Connect the engine harness electrical connector (7) to the back up lamp switch.
  36. Connect the engine harness electrical connector (1) to the VSS.
    37. Fig 13: Identifying Engine Harness Electrical Connectors - Top Of Engine
    GM1647986Courtesy of GENERAL MOTORS CORP.
  37. If equipped with a automatic transaxle perform the following steps, connect the engine harness electrical connector (1) to the park neutral position switch.
  38. Install the engine harness clips to the thermostat housing and engine brackets.
  39. Connect the engine harness electrical connectors (2, 4) to the HO2S.
  40. Install the HO2S CPA retainers.
  41. Connect the ECT sensor electrical connector (1).
    42. Fig 14: Identifying Engine Harness
    GM1647985Courtesy of GENERAL MOTORS CORP.
  42. If equipped with a automatic transaxle, connect the engine harness to the transaxle.
  43. Raise the vehicle.
    44. Fig 15: Installing Engine Harness Terminal To Starter
    GM1656131Courtesy of GENERAL MOTORS CORP.
  44. Install the engine harness lead terminal (1) to the starter solenoid.
  45. Install the engine harness to starter solenoid "S" terminal nut (2).

    Tighten:  Tighten the nut to 3 N.m (27 lb in).

  46. Install the engine harness terminal (3) to the starter.
  47. Install the positive battery cable terminal (4) to the starter.
  48. Install the positive/negative battery cable lead nut (5) to the starter solenoid.

    Tighten:  Tighten the nut to 17 N.m (13 lb ft).

    49. Fig 16: Identifying Engine Harness Clips
    GM1647983Courtesy of GENERAL MOTORS CORP.
  49. Install the engine harness clip (3) to the speed sensor.
  50. Connect the engine harness electrical connector (2) to the VSS.
  51. Install the engine harness clip (1) to the stud.
  52. Install the engine harness clip nut (3) to the engine stud.

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

    53. Fig 17: View Of engine harness electrical connector to A/C compressor and pressure switch
    GM1656130Courtesy of GENERAL MOTORS CORP.
  53. Lower the vehicle.
  54. Reposition and install the AC compressor.

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

  55. Connect the engine harness electrical connector (2) to the A/C compressor.
  56. Connect the engine harness electrical connector (1) to the A/C pressure switch.
    57. Fig 18: Identifying Engine Harness Ground Terminal
    GM1647996Courtesy of GENERAL MOTORS CORP.
  57. Position the engine harness ground terminal to the engine block.
  58. Install the engine harness ground bolt.

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

    59. Fig 19: Locating EVAP Purge Solenoid Electrical Connector
    GM1647981Courtesy of GENERAL MOTORS CORP.
  59. Connect the EVAP purge solenoid electrical connector (2).
  60. Install the engine harness clip (1) to the EVAP purge solenoid bracket.
    61. Fig 20: Connecting KS Electrical Connectors
    GM1656089Courtesy of GENERAL MOTORS CORP.
  61. Connect the following electrical connectors:
    • Knock sensor (3)
    • CKP sensor (1)
    • Oil pressure sensor (2)
    62. Fig 21: Installing Negative Battery Cable Ground Terminal To Stud (RPOs L61/LE5)
    GM1656128Courtesy of GENERAL MOTORS CORP.
  62. Install the negative battery cable ground terminal (2) to the stud.
  63. Install the engine harness ground terminal (3) to the stud.
  64. Install the negative battery cable ground nut (4).

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

    65. Fig 22: View of engine harness clips to camshaft cover
    GM1656114Courtesy of GENERAL MOTORS CORP.
  65. Install the engine harness clips (1 and 2) to the camshaft cover.
    66. Fig 23: Identifying Camshaft Position Actuator Solenoid Valve Electrical Connectors
    GM1647538Courtesy of GENERAL MOTORS CORP.
  66. Connect the intake (3) and exhaust (2) camshaft position actuator electrical connectors.
  67. Connect the ignition coils electrical connectors (1).
    68. Fig 24: View of engine harness clips to intake manifold
    GM1647405Courtesy of GENERAL MOTORS CORP.
  68. Connect the engine harness clips (1, 3 and 4) to the intake manifold.
  69. Connect the engine harness clip (2) to the oil level indicator tube.
    70. Fig 25: Identifying Engine Harness Electrical Connectors
    GM1647528Courtesy of GENERAL MOTORS CORP.
  70. Connect the following electrical connectors:
    • TAC (1)
    • MAP sensor
    • Fuel injector harness (2)
    • Generator (3)
    71. Fig 26: Positioning brake booster vacuum hose clamp at intake manifold
    GM1656109Courtesy of GENERAL MOTORS CORP.
  71. Install the brake booster vacuum hose to the intake manifold.
  72. Position the brake booster vacuum hose clamp (1) at the intake manifold.
    73. Fig 27: Installing Heater Inlet And Outlet Hoses To Thermostat Housing Pipes
    GM1656127Courtesy of GENERAL MOTORS CORP.
  73. Install the heater inlet and outlet hoses to the thermostat housing.
  74. Position the heater inlet (2) and outlet hose (1) clamps at the thermostat housing.
    75. Fig 28: Installing Radiator Outlet Hose To oil Cooler
    GM1656115Courtesy of GENERAL MOTORS CORP.
  75. Install the radiator outlet hose to the oil cooler.
  76. Install the radiator outlet hose to the water outlet.
  77. Position the radiator outlet hose clamp (2) at the oil cooler.
  78. Position the radiator outlet hose clamp (1) at the water outlet.
    79. Fig 29: View Of Radiator Inlet Hose To Engine
    GM1656126Courtesy of GENERAL MOTORS CORP.
  79. Install the radiator inlet hose to the engine.
  80. Position the radiator inlet hose clamp at the engine.
    81. Fig 30: Identifying Cooling Fan Electrical Connector
    GM1647978Courtesy of GENERAL MOTORS CORP.
  81. Connect the cooling fan electrical connector.
    82. Fig 31: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  82. Install the engine drive belt. Refer to Drive Belt Replacement .
  83. Unsecure the cooling module from the upper body structure.
  84. Fill the cooling system. Refer to Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5)) or Draining and Filling Cooling System (GE 47716 Fill) .
    85. Fig 32: Identifying Fuel Line
    GM1647977Courtesy of GENERAL MOTORS CORP.
  85. Connect the EVAP line quick connect fitting (3) to the EVAP purge solenoid. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  86. Connect the fuel feed line quick connect fitting (4) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  87. Install the fuel line clips (1, 2) to the engine brackets.
  88. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  89. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  90. Close the hood.
  91. Road test the vehicle.
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