How to Replace the Throttle in a Chevy Cobaltby Robert Moore
The throttle body on your Chevy Cobalt is held to the intake manifold by four bolts. The procedure to replace it, however, depends on whether you have the naturally aspirated, 2.2-liter four-cylinder engine or the supercharged four-cylinder. Neither engine requires any special tools, but if you have the supercharged engine you'll need a jack and jack stands.
2.0-Liter Supercharged Engine
Position a floor jack under the jack pad in the center of the lower radiator core support. Lift the front end, then position jack stands under the front subframe rails. Lower the Cobalt onto the jack stands.
Open the hood. Loosen the clamp for the air inlet pipe. Disconnect the wiring harness from the intake air pressure and temperature sensor. Remove the vacuum hose from the pipe.
Locate the four bolts for the engine splash shield on the passenger side of the engine -- one bolt points toward the ground and the other three toward the passenger wheel. Remove the bolts and the splash shield.
Loosen the clamp for the intake tube at the intercooler assembly, and lower the tube down to provide access to the throttle body bolts.
Disconnect the wiring harness from the throttle body actuator motor. Remove the four throttle body bolts, then remove the throttle body from the engine. Remove the throttle body gasket.
Install a new gasket and the new throttle body on the intake manifold. Install the bolts and tighten them to 89 inch-pounds with a torque wrench. Plug the wiring harness into the throttle body actuator motor.
Install the intake tube onto the intercooler assembly and tighten the clamp. Install the splash shield and snug the retaining bolts. Lower the vehicle onto the ground.
Install the intake tube onto the throttle body and tighten the clamp. Connect the wiring harness to the air pressure and temperature sensor, then connect the vacuum hose to the intake tube.
Open the hood. Remove the oil fill cap and place it aside. Grasp the sides of the engine cover and pull upward on it to remove it. Install the oil fill cap.
Loosen the clamps at the air filter housing and at the throttle body assembly with a screwdriver. Locate the PCV tube that connects the intake tube to the valve cover. Squeeze the pressure clamp for the PCV tube at the valve cover with pliers, then slide the clamp toward the intake tube.
Locate the push-pin retainer on the driver side of the intake tube assembler, then pry up the center pin. Remove the pin, then lift the intake tube assembly off the engine. Disconnect the wiring harness from the throttle body. Remove the throttle body bolts, then remove the throttle body and gasket from the engine.
Install the new gasket and throttle body. Tighten the bolts to 89 inch-pounds. Connect the wiring harness to the throttle body. Guide the intake tube assembly onto the throttle body while guiding the PCV tube onto the nipple on the valve cover.
Install the push-pin retainer to the intake tube assembly, and push the center pin until it's flush with the base of the retainer. Secure the PCV tube to the valve cover with the pressure clamp. Snug the clamp that secures the intake tube assembly to the throttle body.
Guide the intake tube onto the air filter housing and snug the clamp. Remove the oil cap. Press fit the engine cover onto the engine, then install the oil cap.