Chevrolet Cobalt Service & Repair Manual: Cylinder Head R&R


1. Remove air inlet duct and resonator.
2. Disconnect IAC, TPS and MAP sensor.
3. Disconnect EVAP and PCV hose.
4. Disconnect purge solenoid tube and brake booster hose.
5. Remove oil dipstick tube bolt.
6. Disconnect accelerator and cruise control cables.
7. Remove throttle body and fuel rail.
8. Remove KS connector from intake manifold.
9. Remove mounting nuts, bolts and intake manifold.
10. Remove power steering pump.
11. Remove exhaust manifold heat shield.
12. Remove oxygen sensor.
13. Raise and support vehicle.
14. Remove manifold to exhaust flex decoupler mounting bolts.
15. Pull down and back on exhaust pipe in order to disconnect pipe from exhaust manifold.
16. Lower vehicle.
17. Remove exhaust manifold to cylinder head mounting nuts.
18. Remove exhaust manifold, clean sealing surfaces.
19. Remove timing chain.
20. Drain coolant system into suitable container.
21. Remove cylinder head bolts in sequence, Fig. 1. Discard bolts.
22. Remove cylinder head and gasket.
23. Reverse procedure to install, noting the following:
  a. Install new cylinder head bolts.
  b. Using sequence, Fig. 2, tighten cylinder bolts in two steps: First stop, torque cylinder head bolts to 22 ft. lbs.; second step, tighten head bolts an additional 155°.
  c. Torque front cylinder head bolts to 26 ft. lbs, Fig. 3.

Fig. 1 Cylinder head bolt loosening

Fig. 2 Cylinder head bolt tightening sequence

Fig. 3 Front cylinder head bolt tightening

    Cylinder Head Overhaul
    It is usually recommended to send head to machine shop for complete overhaul. Cylinder head must be cool before removing it from engine. Cylinder head warpage can result if ...

    Emission Control System Inspection
    Caution: Do not remove any component of the engine emission control system. Operating the engine without the engine emission control system intact will reduce fuel economy and engine ...

    See also:

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