2005 Chevrolet 2.0L Cobalt Engine Mechanical Service Repair Manual – PDF DOWNLOAD
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2005 Chevrolet 2.0L Cobalt Engine Mechanical Service Repair Manual – PDF DOWNLOAD
Language : English
Pages : 4914
Downloadable : Yes
File Type : PDF
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2005 Chevrolet 2.0L Cobalt Engine Mechanical Service Repair Manual – PDF DOWNLOAD
DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSTIC STARTING POINT – ENGINE MECHANICAL
Begin the system diagnosis by reviewing the Disassembicd Views , flginc Component Description, Lubrication Description, and New Product Information in Engine Unit Repair. Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation infonnation will also help you determine if the condition described by the customer is normal operation. Refer to Simp,to,ms;E,nginefilcehjmical in order to identify the correct procedure for diagnosing the system and where the procedure is located.
SYMPTOMS – ENGINE MECHANICAL
Strategy Baked Diagnostics
TABLE OF CONTENTS:
2005 Chevrolet 2.0L Cobalt Engine Mechanical Service Repair Manual – PDF DOWNLOAD
2.0L ENGINE………………………………………………………. 1
2.2L ENGINE………………………………………………………. 559
2005 airbags………………………………………………………1134
2005 cobalt steering column…………………………………………1357
2006_Chevrolet_Cobalt_Manual_en_CA…………………………………..1437
2006 Chevrolet Cobalt BookTOC……………………………………1437
Seats and Restraint Systems …………………………………….1443
Front Seats………………………………………………..1444
Manual Seats……………………………………………1444
Driver Seat Height Adjuster………………………………1445
Manual Lumbar…………………………………………..1445
Heated Seats……………………………………………1446
Reclining Seatbacks……………………………………..1446
Head Restraints…………………………………………1449
Easy Entry Seat (Coupe)………………………………….1450
Rear Seats…………………………………………………1452
Split Folding Rear Seat………………………………….1452
Safety Belts……………………………………………….1454
Safety Belts: They Are for Everyone……………………….1454
Questions and Answers About Safety Belts…………………..1458
How to Wear Safety Belts Properly…………………………1459
Driver Position…………………………………………1460
Shoulder Belt Height Adjustment…………………………..1466
Safety Belt Use During Pregnancy………………………….1467
Right Front Passenger Position……………………………1467
Rear Seat Passengers…………………………………….1467
Rear Safety Belt Comfort Guides…………………………..1470
Safety Belt Pretensioners………………………………..1473
Safety Belt Extender…………………………………….1473
Child Restraints……………………………………………1474
Older Children………………………………………….1474
Infants and Young Children……………………………….1476
Child Restraint Systems………………………………….1480
Where to Put the Restraint……………………………….1484
Lower Anchors and Tethers for Children (LATCH)……………..1485
Securing a Child Restraint in a Rear Seat Position………….1490
Securing a Child Restraint in the Right Front Seat Position….1492
Airbag System………………………………………………1495
Where Are the Airbags?…………………………………..1498
When Should an Airbag Inflate?……………………………1501
What Makes an Airbag Inflate?…………………………….1502
How Does an Airbag Restrain?……………………………..1502
What Will You See After an Airbag Inflates?………………..1503
Passenger Sensing System…………………………………1504
Servicing Your Airbag-Equipped Vehicle…………………….1508
Adding Equipment to Your Airbag-Equipped Vehicle……………1509
Restraint System Check………………………………………1510
Checking the Restraint Systems……………………………1510
Replacing Restraint System Parts After a Crash……………..1510
Features and Controls ………………………………………….1513
Keys………………………………………………………1514
Remote Keyless Entry System………………………………1515
Remote Keyless Entry System Operation……………………..1516
Doors and Locks…………………………………………….1519
Door Locks……………………………………………..1519
Power Door Locks………………………………………..1520
Delayed Locking…………………………………………1520
Automatic Door Lock……………………………………..1521
Programmable Automatic Door Unlock………………………..1521
Rear Door Security Locks…………………………………1521
Lockout Protection………………………………………1522
Trunk………………………………………………….1522
Windows……………………………………………………1524
Manual Windows………………………………………….1525
Power Windows…………………………………………..1525
Sun Visors……………………………………………..1525
Theft-Deterrent Systems……………………………………..1526
Content Theft-Deterrent………………………………….1526
PASS-Key® III+………………………………………….1527
PASS-Key® III+ Operation…………………………………1528
Starting and Operating Your Vehicle…………………………..1529
New Vehicle Break-In…………………………………….1529
Ignition Positions………………………………………1530
Retained Accessory Power (RAP)……………………………1532
Starting the Engine……………………………………..1532
Engine Coolant Heater……………………………………1534
Automatic Transaxle Operation…………………………….1535
Manual Transaxle Operation……………………………….1538
Parking Brake…………………………………………..1539
Shifting Into Park (P) (Automatic Transaxle)……………….1541
Shifting Out of Park (P) (Automatic Transaxle)……………..1542
Parking Your Vehicle (Manual Transaxle)……………………1543
Parking Over Things That Burn…………………………….1543
Engine Exhaust………………………………………….1544
Running the Engine While Parked…………………………..1544
Mirrors……………………………………………………1545
Manual Rearview Mirror…………………………………..1545
Automatic Dimming Rearview Mirror with OnStar®……………..1545
Outside Manual Mirror……………………………………1546
Outside Remote Control Mirror…………………………….1546
Outside Power Mirrors……………………………………1546
Outside Convex Mirror……………………………………1547
OnStar® System……………………………………………..1547
Storage Areas………………………………………………1549
Glove Box………………………………………………1549
Cupholder(s)……………………………………………1549
Center Console Storage Area………………………………1549
Driver’s Storage Compartment……………………………..1549
Convenience Net…………………………………………1549
Sunroof……………………………………………………1550
Instrument Panel ………………………………………………1551
Instrument Panel Overview……………………………………1554
Hazard Warning Flashers………………………………….1556
Other Warning Devices……………………………………1556
Horn…………………………………………………..1556
Tilt Wheel……………………………………………..1557
Turn Signal/Multifunction Lever…………………………..1557
Turn and Lane-Change Signals……………………………..1558
Headlamp High/Low-Beam Changer……………………………1558
Flash-to-Pass…………………………………………..1558
Windshield Wipers……………………………………….1559
Windshield Washer……………………………………….1560
Cruise Control………………………………………….1560
Headlamps………………………………………………1563
Wiper Activated Headlamps………………………………..1564
Headlamps on Reminder……………………………………1564
Daytime Running Lamps (DRL)………………………………1564
Fog Lamps………………………………………………1565
Instrument Panel Brightness………………………………1565
Dome Lamp………………………………………………1565
Entry/Exit Lighting……………………………………..1566
Mirror Reading Lamps…………………………………….1566
Battery Run-Down Protection………………………………1566
Accessory Power Outlet(s)………………………………..1566
Ashtray(s) and Cigarette Lighter………………………….1567
Climate Controls……………………………………………1567
Climate Control System…………………………………..1567
Outlet Adjustment……………………………………….1570
Passenger Compartment Air Filter………………………….1570
Warning Lights, Gages, and Indicators…………………………1572
Instrument Panel Cluster…………………………………1573
Speedometer and Odometer…………………………………1574
Tachometer……………………………………………..1574
Safety Belt Reminder Light……………………………….1574
Passenger Safety Belt Reminder Light………………………1575
Airbag Readiness Light…………………………………..1575
Passenger Airbag Status Indicator…………………………1576
Charging System Light……………………………………1578
Up-Shift Light………………………………………….1579
Brake System Warning Light……………………………….1579
Anti-Lock Brake System Warning Light………………………1580
Enhanced Traction System Warning Light…………………….1581
Engine Coolant Temperature Warning Light…………………..1582
Malfunction Indicator Lamp……………………………….1582
Oil Pressure Light………………………………………1585
Security Light………………………………………….1586
Fog Lamp Light………………………………………….1586
Highbeam On Light……………………………………….1586
Fuel Gage………………………………………………1586
Boost Gage……………………………………………..1587
Driver Information Center (DIC)………………………………1588
DIC Operation and Displays……………………………….1588
DIC Warnings and Messages………………………………..1590
DIC Vehicle Personalization………………………………1593
Audio System(s)…………………………………………….1598
Setting the Time………………………………………..1599
Radio with CD (Uplevel)………………………………….1600
Radio with CD (MP3)……………………………………..1607
Theft-Deterrent Feature………………………………….1620
Audio Steering Wheel Controls…………………………….1621
Radio Reception…………………………………………1621
Care of Your CDs………………………………………..1622
Care of the CD Player……………………………………1622
Fixed Mast Antenna………………………………………1623
XM™ Satellite Radio Antenna System………………………..1623
Driving Your Vehicle …………………………………………..1625
Your Driving, the Road, and Your Vehicle………………………1626
Defensive Driving……………………………………….1626
Drunken Driving…………………………………………1627
Control of a Vehicle…………………………………….1630
Braking………………………………………………..1630
Anti-Lock Brake System (ABS)……………………………..1631
Braking in Emergencies…………………………………..1633
Enhanced Traction System (ETS)……………………………1633
Limited-Slip Differential………………………………..1635
Steering……………………………………………….1635
Off-Road Recovery……………………………………….1637
Passing………………………………………………..1638
Loss of Control…………………………………………1639
Racing or Other Competitive Driving……………………….1641
Driving at Night………………………………………..1641
Driving in Rain and on Wet Roads………………………….1642
City Driving……………………………………………1644
Freeway Driving…………………………………………1645
Before Leaving on a Long Trip…………………………….1646
Highway Hypnosis………………………………………..1647
Hill and Mountain Roads………………………………….1648
Winter Driving………………………………………….1650
If Your Vehicle is Stuck in Sand, Mud, Ice, or Snow…………1654
Rocking Your Vehicle to Get It Out………………………..1655
Loading Your Vehicle…………………………………….1655
Towing…………………………………………………….1660
Towing Your Vehicle……………………………………..1660
Recreational Vehicle Towing………………………………1660
Towing a Trailer (Automatic Transaxle)…………………….1663
Towing a Trailer (Manual Transaxle)……………………….1670
Service and Appearance Care …………………………………….1671
Service……………………………………………………1673
Accessories and Modifications…………………………….1673
California Proposition 65 Warning…………………………1673
Doing Your Own Service Work………………………………1674
Adding Equipment to the Outside of Your Vehicle…………….1675
Fuel………………………………………………………1675
Gasoline Octane…………………………………………1675
Gasoline Specifications………………………………….1676
California Fuel…………………………………………1676
Additives………………………………………………1676
Fuels in Foreign Countries……………………………….1677
Filling the Tank………………………………………..1678
Filling a Portable Fuel Container…………………………1680
Checking Things Under the Hood……………………………….1680
Hood Release……………………………………………1681
Engine Compartment Overview………………………………1682
Engine Oil……………………………………………..1685
Engine Oil Life System…………………………………..1690
Engine Air Cleaner/Filter………………………………..1691
Automatic Transaxle Fluid………………………………..1693
Manual Transaxle Fluid…………………………………..1693
Hydraulic Clutch………………………………………..1693
Engine Coolant………………………………………….1694
Coolant Surge Tank Pressure Cap…………………………..1699
Engine Overheating………………………………………1699
Cooling System………………………………………….1701
Windshield Washer Fluid………………………………….1707
Brakes…………………………………………………1708
Battery………………………………………………..1711
Jump Starting…………………………………………..1712
Headlamp Aiming…………………………………………….1716
Bulb Replacement……………………………………………1719
Halogen Bulbs…………………………………………..1719
Headlamps, Front Turn Signal, Sidemarker, and Parking Lamps….1720
Center High-Mounted Stoplamp (CHMSL)………………………1721
Taillamps and Turn Signal Lamps (Coupe)……………………1722
Taillamps, Turn Signal, Stoplamps and Back-up Lamps (Sedan)….1723
Back-Up Lamps (Coupe)……………………………………1724
Replacement Bulbs……………………………………….1725
Windshield Wiper Blade Replacement……………………………1725
Tires……………………………………………………..1726
Tire Sidewall Labeling…………………………………..1728
Tire Terminology and Definitions………………………….1730
Inflation – Tire Pressure………………………………..1733
Tire Inspection and Rotation……………………………..1735
When It Is Time for New Tires…………………………….1736
Buying New Tires………………………………………..1736
Different Size Tires and Wheels…………………………..1738
Uniform Tire Quality Grading……………………………..1738
Wheel Alignment and Tire Balance………………………….1740
Wheel Replacement……………………………………….1740
Tire Chains…………………………………………….1742
If a Tire Goes Flat……………………………………..1743
Changing a Flat Tire…………………………………….1744
Removing the Spare Tire and Tools…………………………1745
Removing the Flat Tire and Installing the Spare Tire………..1750
Storing a Flat or Spare Tire and Tools…………………….1755
Compact Spare Tire………………………………………1758
Appearance Care…………………………………………….1758
Cleaning the Inside of Your Vehicle……………………….1758
Fabric/Carpet…………………………………………..1760
Leather………………………………………………..1760
Instrument Panel, Vinyl, and Other Plastic Surfaces…………1761
Care of Safety Belts…………………………………….1761
Weatherstrips…………………………………………..1761
Washing Your Vehicle…………………………………….1762
Cleaning Exterior Lamps/Lenses……………………………1762
Finish Care…………………………………………….1762
Windshield and Wiper Blades………………………………1763
Aluminum or Chrome-Plated Wheels………………………….1763
Tires………………………………………………….1764
Sheet Metal Damage………………………………………1764
Finish Damage…………………………………………..1764
Underbody Maintenance……………………………………1765
Chemical Paint Spotting………………………………….1765
Vehicle Care/Appearance Materials…………………………1765
Vehicle Identification………………………………………1766
Vehicle Identification Number (VIN)……………………….1766
Service Parts Identification Label………………………..1767
Electrical System…………………………………………..1767
Add-On Electrical Equipment………………………………1767
Headlamp Wiring…………………………………………1768
Windshield Wiper Fuses…………………………………..1768
Power Windows and Other Power Options……………………..1768
Fuses and Circuit Breakers……………………………….1768
Floor Console Fuse Block…………………………………1769
Engine Compartment Fuse Block…………………………….1771
Capacities and Specifications………………………………..1777
Maintenance Schedule …………………………………………..1779
Maintenance Schedule………………………………………..1780
Introduction……………………………………………1780
Maintenance Requirements…………………………………1780
Your Vehicle and the Environment………………………….1780
Using the Maintenance Schedule……………………………1781
Scheduled Maintenance……………………………………1782
Additional Required Services……………………………..1784
Maintenance Footnotes……………………………………1785
Owner Checks and Services………………………………..1786
At Each Fuel Fill……………………………………….1787
At Least Once a Month……………………………………1787
At Least Once a Year…………………………………….1788
Recommended Fluids and Lubricants…………………………1790
Normal Maintenance Replacement Parts………………………1792
Maintenance Record………………………………………1793
Customer Assistance and Information ……………………………..1797
Customer Assistance and Information…………………………..1798
Customer Satisfaction Procedure…………………………..1798
Online Owner Center……………………………………..1799
Customer Assistance for Text Telephone (TTY) Users………….1800
Customer Assistance Offices………………………………1800
GM Mobility Reimbursement Program…………………………1801
Roadside Assistance Program………………………………1802
Courtesy Transportation………………………………….1803
Vehicle Data Collection and Event Data Recorders……………1805
Collision Damage Repair………………………………….1806
Reporting Safety Defects…………………………………….1809
Reporting Safety Defects to the United States Government…….1809
Reporting Safety Defects to the Canadian Government…………1810
Reporting Safety Defects to General Motors…………………1810
Service Publications Ordering Information………………….1810
Index ………………………………………………………..1813
ANTI LOCK BRAKES…………………………………………………..1827
automatic transmission overhaul……………………………………..1891
AXLE SHAFT………………………………………………………..2262
cabin air filter…………………………………………………..2336
CHARGING SYSTEM……………………………………………………2339
CLUTCH……………………………………………………………2474
DISC BRAKES……………………………………………………….2540
DOORS…………………………………………………………….2659
DRUM BRAKES……………………………………………………….2787
ELECTRICAL COMPONENT LOCATOR………………………………………..2837
Engine Controls – 2.2L (L61)_NoRestriction……………………………2910
1…………………………………………………………….2910
2…………………………………………………………….2911
3…………………………………………………………….2912
4…………………………………………………………….2913
5…………………………………………………………….2914
6…………………………………………………………….2915
7…………………………………………………………….2916
8…………………………………………………………….2917
9…………………………………………………………….2918
10……………………………………………………………2919
11……………………………………………………………2920
12……………………………………………………………2921
13……………………………………………………………2922
14……………………………………………………………2923
15……………………………………………………………2924
16……………………………………………………………2925
17……………………………………………………………2929
18……………………………………………………………2946
19……………………………………………………………2949
20……………………………………………………………2951
21……………………………………………………………2953
22……………………………………………………………2954
23……………………………………………………………2956
24……………………………………………………………2959
25……………………………………………………………2962
26……………………………………………………………2964
27……………………………………………………………2967
28……………………………………………………………2968
29……………………………………………………………2970
30……………………………………………………………2972
31……………………………………………………………2976
32……………………………………………………………2980
33……………………………………………………………2983
34……………………………………………………………2985
35……………………………………………………………2994
36……………………………………………………………2996
37……………………………………………………………2999
38……………………………………………………………3003
39……………………………………………………………3007
40……………………………………………………………3009
41……………………………………………………………3012
42……………………………………………………………3017
43……………………………………………………………3018
44……………………………………………………………3020
45……………………………………………………………3022
46……………………………………………………………3024
47……………………………………………………………3028
48……………………………………………………………3030
49……………………………………………………………3034
50……………………………………………………………3038
51……………………………………………………………3042
52……………………………………………………………3043
53……………………………………………………………3045
54……………………………………………………………3048
55……………………………………………………………3052
56……………………………………………………………3054
57……………………………………………………………3056
58……………………………………………………………3058
59……………………………………………………………3062
60……………………………………………………………3065
61……………………………………………………………3068
62……………………………………………………………3071
63……………………………………………………………3074
64……………………………………………………………3076
65……………………………………………………………3079
ENGINE COOLING…………………………………………………….3081
EXHAUST…………………………………………………………..3335
FRAME…………………………………………………………….3373
FRONT SUSPENSION…………………………………………………..3397
HORNS…………………………………………………………….3445
hvac……………………………………………………………..3464
HYDRAULIC DIAGRAMS…………………………………………………3771
LIGHTING SYSTEM……………………………………………………3784
manual transaxle MU3……………………………………………….3943
MANUAL TRANSMISSION GETRAG 5 SPEED…………………………………..4091
OVERHAUL GETRAG 5 speed…………………………………………….4232
OVERHAUL MU3………………………………………………………4413
POWER STEERING…………………………………………………….4590
REAR SUSPENSION……………………………………………………4635
STARTER…………………………………………………………..4685
Wiper-washer_NoRestriction………………………………………….4820
Specifications…………………………………………………4820
Schematics…………………………………………………….4821
Component view 1……………………………………………….4822
Component view 2……………………………………………….4823
Component view 3……………………………………………….4824
Connector End Views…………………………………………….4825
Air Inlet Grille Panel Replacement……………………………….4828
Washer Pump Replacement…………………………………………4831
Windshield Washer Hose Replacement……………………………….4833
Windshield Washer Nozzle Replacement……………………………..4836
Windshield Washer Solvent Container Replacement……………………4838
Windshield Wiper and Washer Switch Replacement…………………….4840
Windshield Wiper Arm Replacement…………………………………4841
Windshield Wiper Blade Replacement……………………………….4844
Windshield Wiper Motor Replacement……………………………….4846
Windshield Wiper Transmission Replacement…………………………4848
Wiper Blade Element Replacement………………………………….4850
WIRING DIAGRAM…………………………………………………….4852
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- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V