Repair manual
Wiring diagrams
Chevrolet Cobalt I Repair Manual
Step-by-step repair and maintenance instructions for the Chevrolet Cobalt I (2004–2010): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- Fastener Tightening Specifications
- End Play Specifications
- Clutch Plate Selection Specifications
- Transmission General Specifications
- Fluid Capacity Specifications
- Torque Converter Assembly Removal
- Transmission Holding Fixture Assemble
- Stub Shaft Removal
- Output Shaft Speed Sensor Removal
- Oil Pan and Gasket Removal
- Oil Filter/Seal, Oil Level Control Valve Removal
- Intermediate/Fourth Servo Removal
- Low and Reverse Servo Removal
- Case Side Cover Removal
- Output Shaft Sleeve Removal
- Oil Pump and Oil Pump Shaft Removal
- Wire Harness Disconnect
- Transmission Fluid Pressure (TFP) Switch Removal
- Control Valve Body Assembly and Gasket Removal
- Spacer Plate and Gasket Removal
- Manual Valve Clip Removal
- Channel Plate and Gasket Removal
- Drive Sprocket, Driven Sprocket, and Drive Link Removal
- Input Speed Sensor Removal
- Wiring Harness Removal
- Driven Sprocket Support Assembly Removal
- Reverse Input Clutch Housing Removal
- Input Carrier and Reaction Gear Assembly Removal
- Input Internal Gear, Forward Clutch Hub Removal
- Forward Clutch and Low/Reverse Band Removal
- Forward Clutch Support, Low Roller Clutch Removal
- Output Shaft and Final Drive Assembly Removal
- Manual Shift Shaft, Detent Lever, and Park Lock Removal
- Transmission Cooler Line Seals Removal
- Torque Converter Seal Removal
- Drive Sprocket Support Removal
- Right Hand Axle Seal Removal
- Case Inspection
- Actuator Guide Replacement
- Drive Sprocket Support Installation
- Torque Converter Seal Installation
- Transmission Cooler Line Seals Installation
- Manual Shift Shaft, Detent Lever, and Park Lock Installation
- Final Drive Assembly Disassemble
- Final Drive Assembly Assemble
- Final Drive Pinion End Play Check
- Fretting Ring, Final Drive Internal Gear Install
- Final Drive and Differential Assembly Install
- Output Shaft Inspect
- Output Shaft Installation
- Forward Clutch Support, Roller Clutch Disassemble
- Forward Clutch Support, Low Roller Clutch Assemble
- Forward Clutch Support, Low Roller Clutch Install
- Forward Clutch Assembly Disassemble
- Forward Clutch Assembly Assemble
- Forward Clutch Assembly Installation
- Input Internal Gear, Forward Clutch Hub Disassemble
- Input Internal Gear, Forward Clutch Hub Assemble
- Reaction Internal Gear, Input Carrier Disassemble
- Input Carrier Pinion Gear Clearance Check
- Reaction Internal Gear, Input Carrier Assemble
- Direct/Coast Clutch, Reaction Carrier Disassemble
- Reaction Carrier Pinion Clearance Check
- Direct/Coast Clutch, Reaction Carrier Assemble
- Direct and Coast Clutch Functional Air Checks
- Selective Washer Measurement and Installation
- Reverse Input and Second Roller Clutch Disassemble
- Reverse Input and Second Roller Clutch Assemble
- Reverse Clutch Functional Air Check
- Reverse Input and Second Roller Clutch Installation
- Intermediate Fourth Band Assembly Installation
- Second Clutch Plate Installation
- Driven Sprocket Support Assembly Disassemble
- Drive Sprocket Support Assemble
- Wiring Harness Connection
- Input Speed Sensor Installation
- Drive, Driven Sprockets and Drive Link Disassemble
- Drive, Driven Sprockets and Drive Link Assemble
- Drive Sprocket, Driven Sprocket, and Drive Link Installation
- Channel Plate Assembly Disassemble
- Channel Plate Assembly Assemble
- Accumulator Springs Installation
- Channel Plate Assembly Installation
- Manual Valve Link Installation
- Checkballs Installation
- Spacer Plate and Gaskets Installation
- Control Valve Body Disassemble
- Control Valve Body Assemble
- Control Valve Assembly and Transmission Fluid Pressure (TFP) Switch Installation
- Oil Pump Cleaning and Inspection
- Oil Pump Assembly Installation
- Side Cover/Gaskets, Disassemble, Assemble, Install
- Side Cover Axle Seal Installation
- Output Shaft Sleeve Assembly Installation
- Stub Shaft Sleeve Assembly Installation
- Right Hand Axle Seal Assemble
- Output Shaft Speed Sensor Installation
- Intermediate/Fourth Servo Disassemble
- Intermediate/Fourth Servo Assemble and Installation
- Low and Reverse Servo Disassemble
- Low and Reverse Servo Assemble and Installation
- Oil Feed Pipes Assemble
- Filter Assembly and Seal Installation
- Oil Pan and Gasket Installation
- Torque Converter Installation
- Park or Neutral - Engine Running (W/o Electronic Range Select Mode)
- Pressure Regulator Valve
- Actuator Feed Limit (AFL) Valve
- Pressure Control Solenoid (PCS) Valve
- Torque Signal Regulating Valve
- Manual Valve
- Automatic Transmission Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly
- 1-2 Shift Solenoid Valve
- 1-2 Shift Valve
- Low and Reverse Servo
- 2-3 Shift Solenoid Valve
- 2-3 Shift Valve
- 3-4 Shift Valve
- Lube 2
- 1-2/3-4 Accumulator Valves
- 1-2, and 3-4 Accumulator Assemblies
- Torque Converter/Cooler and Lube Circuits
- Park or Neutral - Engine Running (With Electronic Range Select Mode)
- Reverse Clutch
- Boost Valve
- A/T Fluid Pressure Manual Valve Position Switch (TFP Val. Position Sw.) Assembly
- Low and Reverse Band Remains Applied
- Reverse (W/o Electronic Range Select Mode)
- Pressure Regulator and Boost Valves
- Pressure Regulator (PR) Valve
- TCC Feed Limit Valve
- TCC Regulated Apply Valve
- TCC Control Valve
- Torque Converter
- Lube 1
- Reverse (With Electronic Range Select Mode)
- Overdrive Range, First Gear (W/o Electronic Range Select Mode)
- Forward Clutch
- Overdrive Range, First Gear (With Electronic Range Select Mode)
- Overdrive Range, Second Gear (W/o Electronic Range Select Mode)
- #2 Checkball (Second Clutch Apply)
- Second Clutch
- 1-2 Accumulator
- 1-2 Accumulator Valve
- TCC Control - Pulse Width Modulated (PWM) Solenoid Valve
- Torque Converter Clutch
- Overdrive Range, Second Gear (With Electronic Range Select Mode)
- Overdrive Range, Third Gear - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode)
- #5 Checkball (Direct Clutch Apply)
- Direct Clutch
- 2-3 Accumulator
- Torque Converter Clutch (TCC)
- Overdrive Range, Third Gear - Torque Converter Clutch (TCC) Not Applied (With Electronic Range Select Mode)
- Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied (W/o Electronic Range Select Mode)
- Intermediate and Fourth Servo
- 3-4 Accumulator
- 3-4 Accumulator Valve
- TCC Control Solenoid Valve
- Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied (With Electronic Range Select Mode)
- Overdrive Range, 4-3 Downshift - Torque Converter Clutch (TCC) Not Applied (W/o Electronic Range Select Mode)
- 1-2/3-4 Accumulator Valve
- Drive Range, Manual Third (from Overdrive Range) (W/o Electronic Range Select Mode)
- Manual Third - Second and First Gears
- Manual Third Gear (With Electronic Range Select Mode)
- Drive Range, Manual Second (from Drive, Manual Third) (W/o Electronic Range Select Mode)
- #6 Checkball (Direct Clutch Release)
- #3 Checkball (Intermediate Band Apply)
- Pressure Control Solenoid Valve
- Manual Second Gear (With Electronic Range Select Mode)
- Drive Range, Manual First (from Drive, Manual Second) (W/o Electronic Range Select Mode)
- #1 Checkball (Low/PRN)
- Manual First Gear (With Electronic Range Select Mode)
- Special Tools
- Transmission Fluid Temperature (TFT) Sensor Specifications
- Fastener Tightening Specifications
- Transmission General Specifications
- Fluid Capacity Specifications
- Range Reference
- Shift Solenoid Valve State and Gear Ratio
- Shift Speed
- Transmission Fluid Pressure (TFP) Manual Valve Position Switch Logic
- Transmission Range Switch Logic
- Line Pressure
- Component Resistance
- End Play Specifications
- Clutch Plate Selection Specifications
- Automatic Transmission Schematic Icons
- Automatic Transmission Inline 20-Way Connector End View
- Automatic Transmission Internal Connector End Views
- Removal Procedure
- Installation Procedure
- Tools Required
- Installation Procedure (Old Switch)
- Installation Procedure (New Switch)
- Adjustment
- Oil Filter and Seal Replacement
- Disassembly Procedure
- Assembly Procedure
- Case Side Cover Seal Replacement
- Replacement Procedure
- Stub Axle Shaft Sleeve and Seal Replacement
- Output Axle Shaft Sleeve and Seal Replacement
- Transmission Mount Inspection
- How to Use This Section
- Basic Knowledge
- Diagnosis
- Transmission General Description
- Transmission Component and System Description
- Transmission Adaptive Functions
- Special Tools
- Fastener Tightening Specifications
- Power Door Systems Connector End Views
- Diagnostic Starting Point - Doors
- Scan Tool Output Controls
- Scan Tool Data List
- Circuit Description
- DTC Descriptor
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Action Taken When the DTC Sets
- Conditions for Clearing the DTC
- Diagnostic Aids
- Symptoms - Doors
- Visual/Physical Inspection
- Intermittents
- Symptom List
- Power Windows Inoperative - Express Down Function
- Power Windows Inoperative - Lockout Function
- Power Window Inoperative - Driver Door
- Power Window Inoperative - Passenger Door (Front)
- Power Window Inoperative - Passenger Door (Rear)
- Power Door Locks Inoperative - All Doors and Switches
- Power Door Locks Inoperative - One Door or Switch
- Power Door Locks Inoperative - Lockout Feature
- Test Description
- Lock Striker Adjustment - Door
- Tools Required
- Removal Procedure
- Installation Procedure
- Power Windows System Components
- Power Window System Controls
- Power Window Motor Operation
- Driver Power Window Operation
- Driver Power Window Express Down Operation
- Front Passenger Power Window Operation
- Rear Passenger Power Window Operation
- Power Window Lockout Operation
- Door Lock System Components
- Door Lock System Controls
- Door Lock and Unlock Operation
- Automatic Door Lock Operation
- Delayed Locking Operation
- Lockout Prevention Operation
- Unlock After Air Bag Deployment
- Power Mirror System Components
- Power Mirror System Controls
- Power Mirror System Operation
- Special Tools
- Fastener Tightening Specifications
- Passenger Car Zoning
- Electrical Symbols
- Basic Knowledge Required
- Checking Aftermarket Accessories
- Circuit Testing
- Using Connector Test Adapters
- Probing Electrical Connectors
- Frontprobe
- Backprobe
- Troubleshooting with a Digital Multimeter
- Tools Required
- Measuring Voltage
- Measuring Voltage Drop
- Measuring Frequency
- Testing for Continuity
- With a DMM
- With a Test Lamp
- Testing for Short to Ground
- Fuse Powering Several Loads
- Testing for a Short to Voltage
- Testing for Intermittent Conditions and Poor Connections
- Testing for Proper Terminal Contact
- Round Wire Connectors
- Control Module/Component Voltage and Grounds
- Temperature Sensitivity
- Electromagnetic Interference (EMI) and Electrical Noise
- Incorrect Control Module
- Salt Water Spray
- High Temperature Conditions
- Low Temperature Conditions
- Duplicating Failure Conditions
- Testing for Electrical Intermittents
- Vehicle Data Recorder
- Circuit Protection - Circuit Breakers
- Circuit Protection - Fusible Links
- Repairing a Fusible Link
- Wiring Repairs
- Repairing Damaged Wire Insulation
- Flat Wire Repairs
- GMLAN Repairs
- GMLAN Connector Terminal Repair
- GMLAN Wire Repair
- High Temperature Wiring
- Identifying High Temperature Wiring
- High Temperature Wire Repair
- Splicing Copper Wire Using Splice Clips
- Splicing Twisted or Shielded Cable
- Splicing Inline Harness Diodes
- SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair
- SIR/SRS Wire Pigtail Repair
- SIR/SRS Wire Repair
- SIR/SRS System Wire Splice Repair
- Connector Position Assurance (CPA)
- Terminal Position Assurance (TPA)
- Connector Repairs
- Identifying Connectors
- Connector Position Assurance Locks
- Terminal Position Assurance Locks
- Terminal Removal Procedure
- Terminal Repair Procedure
- Terminal Replacement Procedure
- Terminal Removal
- Terminal Repair
- Reinstalling Terminal
- Terminal Installation
- Removal Procedure
- Repair Procedure
- Power and Grounding Schematic Icons
- Master Electrical Component List
- Power and Grounding Connector End Views
- Inline Harness Connector End Views
- Splice Pack Connector End Views
- Installation Procedure
- Special Tools