engine CHEVROLET COBALT 2005 1.G Workshop Manual

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-6
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling the Tank..............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-10
Hood Release..............................................5-11
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-15
Engine Oil Life System..................................5-19
Engine Air Cleaner/Filter................................5-21
Automatic Transaxle Fluid..............................5-22
Manual Transaxle Fluid..................................5-22
Hydraulic Clutch...........................................5-23
Engine Coolant.............................................5-23
Coolant Surge Tank Pressure Cap..................5-29
Engine Overheating.......................................5-29
Cooling System............................................5-31
Windshield Washer Fluid................................5-35Brakes........................................................5-36
Battery........................................................5-39
Jump Starting...............................................5-40
Headlamp Aiming...........................................5-44
Bulb Replacement..........................................5-47
Halogen Bulbs..............................................5-47
Headlamps, Front Turn Signal, Sidemarker,
and Parking Lamps....................................5-48
Center High-Mounted Stoplamp (CHMSL).........5-49
Taillamps and Turn Signal Lamps (Coupe).......5-50
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-51
Back-Up Lamps (Coupe)................................5-52
Replacement Bulbs.......................................5-53
Windshield Wiper Blade Replacement..............5-53
Tires..............................................................5-54
Tire Sidewall Labelling...................................5-56
Tire Terminology and Denitions.....................5-58
Ination - Tire Pressure.................................5-61
Tire Inspection and Rotation...........................5-63
When It Is Time for New Tires.......................5-64
Buying New Tires.........................................5-64
Uniform Tire Quality Grading..........................5-65
Wheel Alignment and Tire Balance..................5-67
Wheel Replacement......................................5-67
Tire Chains..................................................5-68
Section 5 Service and Appearance Care
5-1

If a Tire Goes Flat........................................5-69
Changing a Flat Tire.....................................5-70
Removing the Spare Tire and Tools................5-71
Removing the Flat Tire and Installing the
Spare Tire................................................5-75
Storing a Flat or Spare Tire and Tools............5-78
Compact Spare Tire......................................5-80
Appearance Care............................................5-81
Cleaning the Inside of Your Vehicle.................5-81
Fabric/Carpet...............................................5-83
Leather.......................................................5-83
Instrument Panel, Vinyl, and Other Plastic
Surfaces..................................................5-84
Care of Safety Belts......................................5-84
Weatherstrips...............................................5-84
Washing Your Vehicle...................................5-85
Cleaning Exterior Lamps/Lenses.....................5-85
Finish Care..................................................5-85
Windshield and Wiper Blades.........................5-86
Aluminum or Chrome-Plated Wheels................5-86Tires...........................................................5-87
Sheet Metal Damage.....................................5-87
Finish Damage.............................................5-87
Underbody Maintenance................................5-87
Chemical Paint Spotting.................................5-87
Vehicle Care/Appearance Materials..................5-88
Vehicle Identication......................................5-89
Vehicle Identication Number (VIN).................5-89
Service Parts Identication Label.....................5-89
Electrical System............................................5-90
Add-On Electrical Equipment..........................5-90
Headlamp Wiring..........................................5-90
Windshield Wiper Fuses................................5-90
Power Windows and Other Power Options.......5-91
Fuses and Circuit Breakers............................5-91
Floor Console Fuse Block..............................5-92
Engine Compartment Fuse Block....................5-94
Capacities and Specications..........................5-97
Section 5 Service and Appearance Care
5-2

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many uids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle can
affect the airow around it. This may cause wind
noise and affect windshield washer performance. Check
with your dealer before adding equipment to the
outside of your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
If your vehicle has the 2.2L L4 engine, use regular
unleaded gasoline with a posted octane of 87 or higher.
If the octane is less than 87, you may get a heavy
knocking noise when you drive. If this occurs, use a
gasoline rated at 87 octane or higher as soon as
possible. Otherwise, you might damage your engine. A
little pinging noise when you accelerate or drive
uphill is considered normal. This does not indicate a
problem exists or that a higher-octane fuel is necessary.
If you are using 87 octane or higher-octane fuel and
hear heavy knocking, your engine needs service.
If your vehicle has the 2.0L L4 Supercharged engine,
use premium unleaded gasoline with a posted octane of
91 or higher for best performance. You may also use
middle grade or regular unleaded gasoline rated at
87 octane or higher, but your vehicle’s acceleration may
be slightly reduced. If the octane is less than 87, you
may get a heavy knocking noise when you drive. If this
occurs, use a gasoline rated at 87 octane or higher
as soon as possible. Otherwise, you might damage
your engine.
5-5

Gasoline Specications
It is recommended that gasoline meet specications
which were developed by automobile manufacturers
around the world and contained in the World-Wide Fuel
Charter which is available from the Alliance of Automobile
Manufacturers at www.autoalliance.org/fuel_charter.htm.
Gasoline meeting these specications could provide
improved driveability and emission control system
performance compared to other gasoline.
California Fuel
If your vehicle is certied to meet California Emission
Standards, it is designed to operate on fuels that
meet California specications. See the underhood
emission control label. If this fuel is not available
in states adopting California emissions standards, your
vehicle will operate satisfactorily on fuels meeting
federal specications, but emission control system
performance may be affected. The malfunction indicator
lamp may turn on and your vehicle may fail a
smog-check test. SeeMalfunction Indicator Lamp on
page 3-30. If this occurs, return to your authorized GM
dealer for diagnosis. If it is determined that the
condition is caused by the type of fuel used, repairs
may not be covered by your warranty.
Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. In most cases, you should not have to add
anything to your fuel. However, some gasolines contain
only the minimum amount of additive required to
meet U.S. Environmental Protection Agency regulations.
General Motors recommends that you buy gasolines
that are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems
due to dirty injectors or valves, try a different brand of
gasoline. Also, your GM dealer has additives that
will help correct and prevent most deposit-related
problems.
5-6

Filling the Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames, and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.The tethered fuel cap is located behind a hinged fuel
door on the passenger’s side of the vehicle.
To remove the fuel cap, turn it slowly counterclockwise.
The fuel cap has a spring in it; if the cap is released
too soon, it will spring back to the right.
While refueling, hang the tethered fuel cap from the
hook on the fuel door.
5-8

Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense gasoline only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed, or
on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping gasoline.
Checking Things Under
the Hood
{CAUTION:
An electric fan under the hood can start up
and injure you even when the engine is not
running. Keep hands, clothing and tools away
from any underhood electric fan.
{CAUTION:
Things that burn can get on hot engine parts
and start a re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, and plastic or rubber. You or
others could be burned. Be careful not to drop
or spill things that will burn onto a hot engine.
5-10

Engine Compartment Overview
When you open the hood on the 2.2L L4 engine, here is what you will see:
5-12

A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-21.
B. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-15.
C. Engine Oil Dipstick (Out of View). See “Checking
Engine Oil” underEngine Oil on page 5-15.
D. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-36andHydraulic Clutch
on page 5-23.
E. Engine Compartment Fuse Block. SeeEngine
Compartment Fuse Block on page 5-94.F. Remote Positive (+) Terminal. SeeJump Starting on
page 5-40.
G. Remote Negative (−) Terminal. SeeJump Starting
on page 5-40.
H. Engine Coolant Surge Tank. SeeCooling System on
page 5-31.
I. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-35.
5-13

When you open the hood on the 2.0L L4 Supercharged engine, here is what you will see:
5-14