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Home >> Chevrolet >> 2008 >> Cobalt L4-2.2L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Replacement

Engine Replacement



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 inlet duct and resonator . Refer to Air Cleaner Outlet Resonator Replacement .




4. Secure the cooling module to the upper body structure.
5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) 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) (Service and Repair)Cooling System Draining and Filling (2.2L (L61), 2.4L (LE5)) (Service and Repair) .
8. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (2.2L (L61), 2.4L (LE5)) (Service and Repair) .
9. Remove the surge tank to cylinder head hose. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (Service and Repair) and Radiator Surge Tank Outlet Hose/Pipe Replacement (Service and Repair) .
10. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (2.2L (L61), 2.4L (LE5)) (Service and Repair) .




11. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Inlet Hose Replacement (RPOs L61, LE5) and Heater Outlet Hose Replacement (RPOs L61, LE5) .




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 (Service and Repair) .
15. Remove the A/C compressor bolts and set the compressor aside.




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 (RPO L61) (Service and Repair)Exhaust Manifold Replacement (RPO LE5) (Service and Repair) .
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 (Service and Repair) .




24. Remove the side transmission mount. Refer to the appropriate procedure:

* Transmission Mount Replacement - Left Side for the 4T45-E transaxle
* Transmission Mount Replacement - Left Side for the MU3 transaxle
* Transmission Mount Replacement - Left Side for the Getrag 5-speed transmission





25. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .




26. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .





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. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement .




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. 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.



Installation Procedure

1. Attach the engine lift hoist to the engine lift hooks.
2. Install the following components:

* Exhaust manifold-Refer to Exhaust Manifold Replacement (RPO L61) (Service and Repair)Exhaust Manifold Replacement (RPO LE5) (Service and Repair) .
* Engine mount bracket-Refer to Engine Mount Bracket Replacement - Right Side (Service and Repair) .
* Fuel rail-Refer to Fuel Injection Fuel Rail Assembly Replacement .
* Engine block heater, if equipped-Refer to Coolant Heater Replacement (Coolant Heater Replacement) .
* Drive belt tensioner-Refer to Drive Belt Tensioner Replacement (Service and Repair) .
* Thermostat housing and feed pipe-Refer to Engine Coolant Thermostat Replacement (RPO LE5) (Service and Repair)Engine Coolant Thermostat Replacement (RPO L61) (Service and Repair) .
* Generator-Refer to Generator Replacement (RPOs L61/LE5) .
* Flywheel-Refer to Engine Flywheel Replacement (Service and Repair) .

3. If applicable, install the clutch pressure plate and disk.
4. Align the engine to the transmission.





Notice: Refer to Fastener Notice .


Important: The number 3 bolt location is not used.


5. Secure the engine to the transmission.

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

6. If applicable, install the torque converter bolts.

Tighten the bolts to 60 N.m (44 lb ft).





7. Install the starter. Refer to Starter Motor Replacement (RPOs L61/LE5) .
8. Remove the engine lift from the engine.
9. Raise and position the frame and powertrain assembly to the vehicle.
10. Hand start all the frame bolts while aligning the frame to the paint marks.
11. Tighten the frame bolts.

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

12. Remove the lift table.




13. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement .




14. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .




15. Connect the intermediate steering shaft to the steering gear. Refer to Steering Gear Replacement .




16. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .




17. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .




18. Install the side transmission mount. Refer to the following:

* Transmission Mount Replacement - Left Side for the 4T45-E transaxle
* Transmission Mount Replacement - Left Side for the MU3 transaxle
* Transmission Mount Replacement - Left Side for the Getrag 5-speed transmission





19. Install the engine mount. Refer to Engine Mount Replacement (Service and Repair) .
20. Remove the wood blocks between the powertrain and frame.
21. Connect the transmission shift cable to the transmission.
22. Connect the transmission harness connector.




23. Connect the exhaust takedown pipe to the exhaust manifold.

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

24. Connect the generator harness connectors.

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





25. Connect the starter harness connectors (3, 4, 5).

* Tighten the battery terminal nut to 17 N.m (13 lb ft).
* Tighten the S-terminal nut to 3 N.m (27 lb in).


26. Install the AC compressor to the engine. Refer to Air Conditioning Compressor Replacement (LNF) Air Conditioning Compressor Replacement (L61, LE5) .
27. Install the engine drive belt. Refer to Drive Belt Replacement (Service and Repair) .
28. Connect the following harness connectors:

* IAC motor
* TPS
* MAP sensor
* Crankshaft sensor
* Oil pressure sensor
* Purge solenoid
* Ignition coil and module assembly
* O2 sensor
* Vehicle speed sensor
* Engine temperature sensor





29. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Inlet Hose Replacement (RPOs L61, LE5) and Heater Outlet Hose Replacement (RPOs L61, LE5) .
30. Install the radiator outlet hose. Refer to Radiator Inlet Hose Replacement (2.2L (L61), 2.4L (LE5)) (Service and Repair) .
31. Connect the fuel line to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
32. Connect the brake booster hose at the brake booster.




33. Release the cooling module from the upper body structure.
34. Install the air inlet duct and resonator. Refer to Air Cleaner Outlet Resonator Replacement .
35. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
36. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations .
37. Fill the cooling system. Refer to Cooling System Draining and Filling (GE 47716 Fill) (Service and Repair)Cooling System Draining and Filling (2.2L (L61), 2.4L (LE5)) (Service and Repair) .
38. Road test the vehicle.


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