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2007 Chevrolet Cobalt

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1K views176 pages

2007 Chevrolet Cobalt

Uploaded by

gary montini
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© © All Rights Reserved
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Chevrolet 7 nl ‘hla Cobalt Table of Contents Product Information 2007 Chevrolet Cobalt Big Lineup Of Small Cars Gets More Power, Features And Accessories, Expressive design wn. - so Dynamic driving experience and safety Safety and security, Plentiful powertrains Cobalt SS..... Cobalt SS Supercharged Coupe Interior refinement and comfort... Get personal New for 2007... Mode! Lineup. Specification... Overview Engines Transmission... Chassis/Suspension Brakes... Wheels/Tires Dimensions. Exterior Interior Capacities sn Vehicle Identification... 10 Vehicle Identification 10 VIN Derivative... se "1 Engine ID and VIN Derivative Location ... 12 Transmission ID and VIN Derivative Location... oe 4740-E/4T45-E Transmission ID Location — oe Getrag 5T45-E Transmission VIN Location, M86 .. sonn 16 Label - Vehicle Certification, Tire Place Card, Anti-Theft and Service Parts ID... 7 Vehicle Certification Label een nnn Tire Placard Service Parts ID Labe... Anti-Theft Label RPO Code List. Technical Information Maintenance and Lubrication... Capacities - Approximate Fluid... ennnnnnnnnnnnnnnnnnnnnninnnnnnnnnns 22 Cooling System. snnne BB Intercooler System 2.0L Engine = RPO LSW wnnnnnsesnnmmnnnnnnnnnnnnienannnneee BB Engine Oil With Filter Fuel Tank, Transmission/Transaxle. Maintenance Items Engine Air Cleaner'Filter. Engine Oil Filer Spark Piugs.... snnnnnnnnnnnnnnnnnns so Passenger Compartment Air Filter svenmnennes BB Windshield Wiper Blade (Hook Type).. 22 Fluid and Lubricant Recommendations. 23 Page Descriptions and Operations Stoeting son Power Steering System Torque Sensor. EPS Moto? 0. Power Steering Control Module SCH. Steering Wheel and Column... Vehicle Steering... Vehicle Security:Some Vehicle Models Driver Convenience. so Driver Safety. Ignition Lock Cylinder Control Actuator. ‘Suspension Description and Operation. Front Suspension Rear Suspension.. ‘Axle Assembly Coil Springs . ‘Shock Absorber. : Wheel Bearing/Hub Acsomby Wheels and Tires. oo General Description. Tread Wear Indicators Description... Metric Wheel Nuts and Bolts Description Tire Infition Description... = Inflation Pressure Conversion (eopascas oP P-Metric Sized Tires Description... Driveline/Axte : ‘Wheel Driveshafts Seal and Clamp.. Inner Joint Outer Joint on Intermediate Drive Vehicle Speed Senscr... Braking System Description and Operation Hydraulic Brake System Description and Operation... System Component Description... Hydraulic Brake Master Cylinder Flu Hydraulic Brake Master Cylinder... - Hydraulic Brake Pressure Balance Control System. Hydraulic Brake Pipes and Flexible Brake Hoses Hydraulic Brake Wheel Apply Components.. System Operation .nn.0 Brake Assist System Description and Operation. ‘System Component Description. - Brake Pedal... - Brake Pedal Pushrod.. Vacuum Brake Booster Vacuum Source... Vacuum Source Delivery System . System Operation.. Disc Brake System Description and Operation... System Component Description... : Disc Brake Pads Disc Brake Rotors... Disc Brake Pad Hardware . Disc Brake Caliper Hardware System Operation. Drum Brake System Description and Operation.. ‘System Component Description. Drum Brake ShOGS nnn Brake Drums Drum Brake Hardware... Drum Brake Adjusting Hardware System Operation. Park Brake System Description and Operation ‘System Component Description. Park Brake Lever Assembly Park Brake Cables. Park Brake Cable Equalizer... Park Brake Apply Lever Park Brake Actuator/Adjuster . Drum Brake Shoes System Operation. 7 ‘ABS Description and Operation... ‘Antilock Brake System Engine Description and Operation. Engine Mechanical ~ 2.0L. General Specifications... General Data... Balance Shaft. BOCK sree Camshaft... Connecting Rod Crankshaft... Cylinder Head Lubrication System Piston Rings.. Pistons and Pins. Valve System... Fastener Tightening Specifications Engine Component Description Cylinder BlOoK Crankshaft Connecting Rod and Piston Oil Pan Balance Shaft Assembly... Cylinder Head Valves Camshaft Valve Lifters . Camshaft Cover... Camshaft Drive. Intake and Exhaust Manifold Supercharger Description and Operation... Description Operation InterCO0IeF rn Lubrication Description... Grankcase Ventilation System Description . General Description se Operation Results of Incorrect Operation Page ti Engine Mechanical ~ 2.21. - L61 General Specifications... General Data. Balance Shaft BIOCK oon Camshattnnnsenn Connecting Rod . Crankshatt. Cylinder Head Lubrication System Piston Rings. Pistons and Pins . Valve System... Fastener Tightening Specifications Engine Component Description. Cylinder Block. Crankshatt..n Connecting Rod and Piston... Ol Pan Balance Shaft Assembly... Cylinder Head Valves... Camshaft. Valve Liter rnin Camshaft Cover: Camshaft Drive on. Intake and Exhaust Manifold Lubrication Description Drive Belt System Description. Crankcase Ventilation System Bescrpion General Description... sn Oper Results of Incorrect Operation... Engine Mechanical - 2.4L... General Specifications... General Data. Balance Shaft BOCK... Camshaft ‘Connecting Rod... Crankshaft Cylinder Head... Lubrication System Piston Rings. Pistons and Pins Valve System. Fastener Tightening Specifications Engine Component Description.. Cylinder Block Crankshaft nnn Connecting Rod and Piston OL PAN vn “ Balance Shaft Aesembiy. Cylinder Head . 7 Valves Valve Lifters. Camshaft Cover Camshaft Drive. Intake and Exhaust Lubrication Description. Engine Cooling nn. Fastener Tightening Specifications Cooling System Description and Operation. Coolant Heater... Cooling System ‘Charge Air Cooling System (LSJ Only)... Cooling Cycle... Coolant Radiator.. Pressure Cap... Coolant Recovery System. Air Baffles and Seals... Water PUMP.nnnnnsnennnn Thermostat Engine Oil CoOler neon Transmission Oil Cooler: Engine Electrical ....nn Fastener Tightening Specification Battery Usage .. on Generator Usage... Battery Description and Operation. Battery Ratings Reserve Capacity Cold Cranking Amperage .. Circuit Description Starting System Description and Operation... Circuit Description... Charging System Description and Operation wi Electrical Power Management (EPM) Overview Charging System Components GeNETAOT Body Control Module (BCM). Battery Current Sensor... Engine Control Module (ECM) Instrument Panel Cluster (IPC) Charging System Operation Charge Mode... Fuel Economy Mode. Voltage Reduction Mode Start-up Mode... Windshield Deice Mode. Battery Sulfation Mode... Instrument Panel Cluster (IPC) Operation .. Charge Indicator Operation Charging System Faure Battery Voltage Battery Saver Active : Charging System Deserplion ‘and Operation without RVC... Generator wn so ssn Regulator. Circuit Description .. Charging System Indicator... fold Engine Controls sents ” Fu Sytem Specifications ~ All Engines.. feces TH Engine Controls - 2.0L... 2 Ignition System Specifications... 2 Fastener Tightening Specifications ...m sunmnnnennnnnnnntnnnnnnnnannanns TZ Engine Controls - 2.2L (L61) 73 Ignition System Specifications. sonnnnsnnninnnninnnnnnnnnnnnn snes TB Fastener Tightening Specifications. : ere) Engine Controls - 2.41. svnnnnnnnnnnnnnn 74 Ignition System Specifications... See seen TA Fastener Tightening Specifications. son %4 Exhaust System... 75 Fastener Tightening Specifications... : een 75) Eahauat Sytem Description one 75 ReSONALOF nnn nnn sennnnmnnnennneanee 1S Catalytic Converter svn 76 Muffler. 76 ‘Transmission/Transaxie Description and Operation 77 Manual Transmission - Getrag 5-Speed. 7 Fastener Tightening Specifications .. 7 Lubrication Specifications... 7 Transmission General Description. 78 Manual Transaxle MUS. 79 Fastener Tightening Specifications 79 Lubrication Specifications... . 80 Transmission System Description and Operation. Lubrication Flow. Power Flow... Clutch... Fastener Tightening Specteations. Hydraulic Clutch Description... ‘Clutch Spin Down Time Clutch Driving Members Clutch Driven Members Hydraulic Clutch Fluid... Hydraulic Clutch Operating Members. ‘Automatic Transaxle - 4T45-E Transmission General Specifications... Fastener Tightening Specifications Fluid Capacity Specifications - Approximate. Transmission General Description Transmission Component and System Description . ne 86 ‘Adapt Function sven 86 tee Reerlasioa Sta Leek Conta Deseo and nd Operation 87 Abbreviations and Meanings. Conversion - Englsh/Metrc. Equivalents - Decimal and Metric. Fasteners. . Metric Fasteners Fastener Strength Identification Prevailing Torque Fasteners... come - se All Metal Prevailing Torque Fasteners sein | Nylon interface Prevailing Torque Fasteners. sl ‘Adhesive Coated Fasteners. a Metric Prevaling Torque Fastener Minimum Torque Development sell ‘All Metal Prevailing Torque Fasteners oo it Page w Nylon Interface Prevailing Torque Fasteners. English Prevailing Torque Fastener Minimum Torque Development . All Metal Prevailing Torque Fasteners Nylon Interface Prevailing Torque Fasteners... Page vi Page vii 2007 Chevrolet Cobalt Restoration Kit Product Information 2007 Chevrolet Cobalt: Big Lineup of Small Cars Gets More Power, Features And Accessories ‘The Cobalt lineup of premium, sporty compact cars offers more horsepower, features and accessories for the 2007 model year. Already a popular nameplate known for delivering affordable performance ard refinement, Cobalt offers a high number of configurations as diverse as the customers who seek and buy ‘small cars. Cobatt's expressive design, dynamic driving experience and wide array of features appeal to a diverse audience ~ from those desiring a feature-packed, fuel-efficient, value-driven commuter to the youthful sport compact enthusiasts who view their car as a canvas for personalization. It has quickly earnec a following by outperforming competitors in key areas including horsepower, features and value proposition. Cobalt sales in 2005 totaled more than 212,000 unit. For 2007, Chevy offers eight Cobalt models: the LS, LT, LTZ and SS sedan; and the LS, LT, SS and SS Supercharged coupe. This broad portfolio includes three different GM-proven Ecotec engines, ranging from 148 horsepower (110kW) to 205 horsepower (153 kW), three transmissions and three suspensions. The 2.21 and 2.4L Ecotecs get a slight horsepower increase for 2007. This new model year Chevrolet Accessories provides Cobalt customers with an expanding range of personalization tools that include popular horsepower-boosting stage kits. Cobalt features a strong foundation, rigid body structure, well-isolated chassis and low interior noise levels, thanks in part to the use of Quiet Stee! laminated sheetmetal, a premium material not normally found on vehicles in the compact segment. The strong foundation also enhances occupant protection. Precise electric steering, tuned to each tire/wheel combination, further contributes to the dynamic criving ‘experience. T he Cobalt range of sedans offers stylish looks coupled with a comfortable ride. The Cobalt coupe design mimics the sedan from the A-pillar forward, but differs from the A-pillar rearward with a tapered reverse C-pillar that leads to Corvette-inspired four round taillamps. Several wheel options also are offered, including standard 15-inch wheels and avaliable 16-inch, 17-inch and 18-inch wheels, all with unique designs. Cobalt’s exterior color palette for 2007 now includes a new Sport Red Tint. Expressive design ‘With a rakish yet refined silhouette and excellent attention to detail, Cobalt has a stylish design that reflects its sporty, fun-to-drive character. ‘Available in coupe and sedan body styles, Cobalt features smooth and sleek exteriors with fast rooflines. Cobalt is light in the air, 100, with a coefficient of drag of just 0.324 for both body styles. A myriad of subtle details, such as aircraft-style doors that integrate the door frames into the exterior surface for a tighter, flush fit, contribute to Cobat’s overall feeling of strength and solidity. Jewel-like headlamps and taillamps exude a premium appearance. The coupe features additional upscale cues, such as Corvette-inspied taillamps. A sporty look for all models is achieved with a low-slung body and a curvaceous roofline; particularly in the coupe, which has tapered, reverse C-pilars that lead to Chevy's signature four round taillamps. Cobatt's other carefully executed design details include: + Monochromatic details on all models, including door handles, bumpers, grille, B-pillars and roof ‘molding for a more finished look + Single-cavity headlamps with all forward lighting functions contained in the same unit (except foglamps) * Different fascias for sedans and coupes creates distinction in lineup + Chevy-signature horizontal grille bar and gold bowtie insignia for base, LS and LT models + Available stanchion-mounted rear spoiler Page 1 2007 Chevrolet Cobalt Restoration Kit ‘Available 16-inch high-vent steel wheels for LT ‘Available 18-inch high-polished wheels for SS Supercharged Body-color ground effects fascias and rocker moldings for SS Supercharged Front wheelhouse liners with molded-in mudistone guards for LS and LT models Nine available exterior colors Dynamic driving experience and safety From the outset, engineers designed Cobalt to be a responsive, fun-to-drive car. Cobal’s underbody uses high-strength steel as welded members in strategic locations for maximum strength, structural integrity, ‘mass optimization and crashworthiness. The underbody boasts a rigid bending frequency of nearly 27 Hz. ‘All Cobalt models feature a strut-type front suspension, semi-independent torsion beam rear suspension, and front and rear stabilizer bars for more exact body roll control. Speed-sensitive electric power steering is tuned to match the performance levels ofthe various tire and suspension packages. ‘The Cobalt rides on a MacPherson strut front suspension and a semi-independent, torsion beam rear suspension. Front and rear stabilizer bers — uncommon features for compact cars in Cobalt's price cange ~ are standard on all models. Suspension tuning for each model, including steering feel, spring rate and stabilizer bar diameter, is dialed in to provide distinct driving and handling characteristics. Three suspension settings are available: FE1 suspension - standard on LS, LT and LTZ models, it provides a smooth ride and includes a 19- mm front stabilizer bar and a 16-mm rear stabilizer bar FES suspension - standard and available only on SS models, it delivers a firmer, more direct de and includes 22-mm front and rear stabilizer bars, four-wheel disc brakes, monotube shocks ard 17- inch wheels and performance tires FEG cuspension — standard on the SS Supercharged, it was developed on the racetrack to deliver sports car levels of handling and grip; 24-mm front stabilizer bar and 22-mm rear stabilizer bar, higher-rate springs and bushings, four-wheel disc brakes, monotube shocks and 18-inch forged aluminum wheets with complementing performance tires Cobalt's struttype front suspension is compact yet provides long whee! travel, with 90 mm of ‘compression travel and 87 mm of rebound, which is substantially more than most competitors and ‘enhances overall ride and handling. Monotube rear shocks are used for a more precise road feel. L- shaped front control arms contain a forward pivot bushing, which transmits most of the cornering force, and a larger, high-damped composite rear elastomeric bushing that allows rearward movement to minimize harshness from road surface impacts. The front control arms are made from stee! on the FE1 suspension and are aluminum on the FE3 and FES suspensions. ‘The direct-acting front stabilizer bar connects to each strut for precise steering response and improved ‘cornering agility with decreased body roll. All front suspension components are mounted to a new, rigid cradle assembly comprised of four large hydroformed steel tubes and two side members that are integrally welded to front and rear cross members. The cradle is mounted to the Cobalt’s space fran at four widely spaced points. Cobatts torsion beam rear suspension provides excellent ride and handling, while maximizing interior space. A hydraulic rear suspension bushing is employed on the FE1 suspension to improve the ride and suppress road noise. Rear wheel travel, at 126.5 mm in jounce and 68.5 mm in rebound, is longer than most vehicles in the segment. Vented front disc brakes with single-piston calipers and composite rear drum brakes are standard on LS, LT and LTZ. Four-wheel anti-lock brakes (ABS) are standard on LT and LTZ models, and optional cn LS, Four-wheel disc brakes with ABS are standard on SS and SS Supercharged models. Cobalt also offers, ‘an enhanced electronic traction control system on all models equipped with an automatic transmission and ABS; this system is standard on LTZ. Enhanced traction system (ETS) is integral with automatio-equipped Coballs with ABS. ETS enhances traction by adjusting engine torque if wheel slip is detected, Page 2 2007 Chevrolet Cobalt Restoration Kit Safety and security The tigid body structure that lays the foundation of Cobalt’s dynamic driving experience also reinforces occupant safety. In addition to the solid unibody structure, dual-stage frontal air bags are standard and side head curtain air bags are available, Front seat belt pretensioners, rear center shoulder belts and the LATCH child seat retention system are also standard. ‘Additional security is provided by the standard PASS-Key Ill Plus thefl-deterrent system, which prevents vehicle operation if the right key is not used. Remote keyless entry and power door locks (not available on LS) provide lockout prevention, delayed locking and programmable operation. Continuous safety is provided by OnStar. OnStar-equipped Cobalt models feature OnStar dual-mode (analog-digital) equipment. OnStar's digital equipment also includes enhanced hands-free voice recognition capabilities including more intuitive continuous digit dialing and improved voice recognition accuracy. OnStar is the leading provider of in-vehicle safety, security and information services in the United States and Canada . Using the GPS satellite network and wireless technology, OnStar features, core safety services and OnStar Hands-Free Calling that allow drivers to make and receive voice- activated phone calls using an externally mounted antenna for greater reception. ‘The OnStar service standard on the 2007 Cobalt includes the General Motors Advanced Automatic Crash Notification (AACN) system (excluding SS models), making crash data available to the participating 911 centers to help them dispatch the appropriate live-saving personnel and equipment to crash scenes faster. Plentiful powertrains Cobalt offers buyers a variety of segment-leading powertrain combinations that deliver distinct levels ranging from maximized economy to race-inspired performance. Cobalt's GM-proven Ecotec 2.2L and 2.4L engines receive slight horsepower increases for 2007. ‘The 2.21 engine of the LS, LT and LTZ models is rated at 148 horsepower (110 kW) at 5600 rpm* and 152 lb.-ft. of torque (260 Nm) at 4200 rpm.* Cobalt SS features a 2.4L engine rated at 173 horsepower (129 kW) at 6200 rpm* and 163 lb.-ft. of torque (221 Nm) at 4800 rpm." The 2.0L SC engine of the Cobalt SS Supercharged produces 205 horsepower (153 kW) and 5600 rpm and 200 Ib. of torque (272 Nm) at 4400 rpm. ‘All Cobalt engines are from the technically sophisticated Ecotec family. Each has distinct performance ‘and hardware differences, but all share a basic all-aluminum architecture and construction that includes: Dual overhead camshafts (DOHC) and four valves per cylinder ‘Twin counter-rotating balance shafts Low-rition, roler-finger follower valvetrain with hydraulic lash adjusters Zero-maintenance chain camshaft drive Extremely compact dimensions and low mass Direct mounting of all accessories to the engine structure to eliminate common sources of noise, vibration and harshness + Full circle transmission attachment is more rigid than most 4-oylinder powertrains for reduced noise and vibration ‘+ GM Oil Life System for optimum oil change frequency + No routine maintenance apart from oilfilfiter changes * Catalyst located close to the exhaust manifold to speed catalyst “light-off" and reduce hydrocarbon emissions * Innovative cast-in ol fiter housing eliminates crawling under the car to perform oil changes The design also eliminates throwaway oll-fiter “cans” that retain used oll and typically end up in landfils ‘The Cobalt's standard transmission on LS, LT and SS is a Getrag F23 five-speed manual, known for ‘smooth shifting, The F35 five-speed manual transmission in the SS Supercharged has a higher torcue capacity than the manual transmission found in other Cobalt models. A short-hrow shifter and 4.05 1 axle Page 3 2007 Chevrolet Cobalt Restoration Kit ratio complement the performance-oriented transmission and performance characteristics of the engine, giving the Cobalt SS Supercharged exhilarating acceleration, Available on LS, LT and SS models and standard on LTZ is the Hydra-Matic 4745 electronically controlled four-speed automatic transmission. Like the standard F23 manual transmission, the 4T45 is. renowned for its smooth and durable operation. In the Cobalt, this transmission uses full perimeter fastening directly to the engine block and oil pan to increase driveline stiffness, resulting in reduced noise and vibration, The 4T45 uses the new Dexron VI fluid and is “fled for life,” meaning there is no scheduled ‘maintenance required for the transmission under normal operating conditions. Cobalt SS Cobalt SS invokes Chevy's performance heritage, and is part of a larger family of Chevy SS models. Highlights of the SS coupe and sedan models include: 2.4L Ecotec VVT four-cylinder with 173 horsepower (129 KW) and 163 lb.-ft. of torque (221 Nm)* Standard five-speed manual transmission Available Hydra-Matic 4T45 four-speed electronically controlled automatic transmission ‘Seventeer-inch alloy wheels and performance tires Performance-tuned suspension Standard four-wheel disc brakes with four-channel ABS system ‘SS-specific front and rear fascias, rocker moldings (similar to SS Supercharged) SS exterior badging ‘+ SS-specific interior appointments, including instrument panel appearance and trim Cobalt SS Supercharged Coupe With impressive performance from its 205-horsepower (153 kW) 2.0L supercharged Ecotec engine, this ‘compact powerhouse is at home on the racetrack as well as the street. The suspension was tuned at Germany's Nurburgring racetrack. At the heart of the Ecoteo 2.0L SC is an Eaton M62 supercharger. Maximum supercharger boost pressure is 12 pounds per square inch (psi), and the system includes an air-to-water intercooler that cools the incoming air charge to increase intake-charge density, which in turn enhances power and reduces the engine's propensity to “knock” at high boost levels. Cobalt SS Supercharged achieves 0-60 mph in 6.4 seconds, and the quarter-mile in 14,9 seconds, with a top speed of 143 mph, It features distinctive exterior and interior elements that also make it stand out from the crowd, including a high-mount spoiler, lower rocker extensions and fascias with one-inch extensions; as well as titanium- face gauges, A-pillar-mounted boost gauge and leather- appointed seats with perforated color-keyed inserts Interior refinement and comfort Separate trim levels for each Cobalt model provide distinction and a tailored appearance. In keeping with Cobait’s premium positioning, many features are standard, including air conditioning and electric rear defogger. New for 2007 is an AMIFM stereo radio and CD player with MP3 playback and auxiliary input jaok; and driver information center. Surprising amenities - such as an optional remote vehicle starter system new for 2007 (when an ‘automatic transmission is ordered) - also lend an upscale feel to the Cobalt’s interior, as many of tre standard and available features aren't generally found within the vehicle's competitive set. The available factory-installed remote vehicle starter system, which is new for 2007, is integrated wth the remote keyless entry feature and allows the driver to get a head start on the car's interior heating and cooling from a range of up to 200 feet (61 m). ‘Additionally, Cobalt features plenty of interior comfort and flexibilty, including easy access to the rear seat, 60/40 folding rear seats and interior access to the trunk area, as well as ample, versatile storage. Page 4 2007 Chevrolet Cobalt Restoration Kit Available features include power sunroof, XM Satellite Radio (continental U.S. only), AM/FM sterec with six-disc in-dash CD player, MP3 playback and auntliary input jack (new for 2007); seven-speaker Pioneer Premium Audio System and OnStar. Other interior highlights include: ‘+ Four trim levels for three Cobalt models: LS, LTZ and SS, three trim levels for LT + Height-adjustable three-spoke steering wheel (new for 07) ‘+ Adjustable front head restraints ‘+ Four cupholders in the center console; two for front-seat passengers, two for rear-seat passengers Pivoting center armrest has contoured top to faciitate easy, comfortable manual shifting; interior of console holds five CDs Numerous storage areas, including large, bin-ike glove box Unique gauge cluster with A-pillar boost gauge on SS Supercharged Driver's foot rest Height-adjustable driver's seat Extensive applications of acoustic materials throughout Cobalt interiors reflect a focus on ride comfort, with quality materials and stylish appointments throughout. ‘The seats are designed to reflect the performance level of each model. Cloth bucket seats are standard on LS, while sport cloth seats with driver's lumbar adjuster are standard on LT and SS. Leather-appointed heated seats with leather-trimmed steering wheel and shift knob are available on LT and SS, and standard on LTZ. Leather-appointed seats with color-keyed perforated inserts, recliners and driver's manual lumbar are standard on SS Supercharged. Racing-inspired, leather-accented Recero bucket seats are available on the SS Supercharged when the Performance Package is ordered. Get personal Because Cobalt attracts such a diverse group of customers who define style in their own way, Chevrolet Accessories offers accessories and performance parts Cobalt owners can use to personalize their vehicles, Customers can add some extra juice to the already powerful Cobalt SS coupe with Stage One and Stage ‘Two supercharger kits, introduced in 2005, The Stage One kit includes higher-flow fuel injectors and an ECU calibration to provide 31 extra horsepower (for a total of 236 hp and 206 lb.-ft. of torque). Add the Stage Two kit, with its smaller supercharger pulley and shorter drive belt, and the engine kicks out 241 horsepower (180 kW) and 218 Ib.-ft. (301 Nm) of torque. In addition, owners canmake noise with a Cobalt-validated GM Performance Exhaust System, consisting of a semi-polished muffler constructed of T-04 stainless steel with mandrel-bent tubing. Choose the throaty purr of the Touring system or the aggressive grow of the Performance system. When properly installed, this system will comply with local and state ordinances. Other Chevrolet Accessories available for Cobalt include highly polished chrome exhaust tips, a race- inspired, high-profile or more subtie lower-profile rear spoiler; and brushed aluminum pedals with raised rubber traction surfaces + Preliminary, pending corticaton. A new voluntary power and torque cortication procedure developed by the SAE Engine Test Code committee was approved March 31, 2005. This procedure (J2723) ensures fa, accurate raings far horsepower and frque by alowing manufacturers o cert ther engines through tic-parly wihess testing. GM was the fst auto manufacturer fo begin Using the procedure and expocts fo use i forall newly rated engines in the future. Page 5 2007 Chevrolet Cobalt Restoration Kit New for 2007 ‘Three-spoke steering wheel Available 16-inch high-vent steel wheels on LT New exterior color: Sport Red Tintcoat Model Lineup Horsepower increases on models with 2.2L and 2.4L Ecotec engines Available remote vehicle starter system on automatic transmission-equipped models Available AM/FM stereo with six-disc in-dash CD changer and MP3 playback Standard AM/FM stereo with CD player and auxiliary input jack Eighteen-inch high-polished wheels available on SS Supercharged coupe Engines Transmissions [Ecotec 2.2L /Ecotec 2.4L [Ecotec 20L| S-speed | 4-speed ba WT 4 SC manual | automatic [Cobalt LS coupe & sedan s = 8 ° ‘obalt LT coupe & sedan S s a (Cobalt LTZ sedan. = s ° [Cobalt SS coupe & sedan = s ~o. (Cobalt SS Supercharged _ _ : s _ pe Standard $ Optional ° Notavalable —~ Page 6 2007 Chevrolet Cobalt Restoration kit Specifications Overview Models: LS coupe and sedan, LT coupe and sedan, LTZ sedan, SS ‘coupe and sedan, SS Supercharged coupe Body style / driveline S-passenger sedan and coupe, unitized frame, front engine, front-wheel drive struction: Gi 2-sided galvanized steel on exierior panels (except roof) EPA vehicle Gass compact-size car - ‘Manufacturing location: —__[ Lordstown, Ohio ~ -I Key competiors Honda Civic, wagon Joa, Ford Fosus, Toyola Cova lazda 3 _ Engines Ecotec 2.2L (L61) Ecotec 2.4L VVT (LES) | Ecotec 2.0L SC (LSJ) lApplication [sid on tS,UT and [TZ | std on Cobalt SS | std on SS Supercharged iType:. 2.2L DOHC |-4 Z4L DOHC VVTI-4 | 2.0LDOHCSCI-4 | Disecomer fe aE 1134/7189 145 / 2384 122 1 1908 re & stroke (in/mm): | 330%372/86x046 | 346x385 /68x08 | 3.30x3.30/ 86x60 Block material ‘cast aluminum ‘east aluminum ‘cast aluminum _ (Cylinder head material: — ‘east aluminum cast aluminum ‘east aluminum falvetrain: overhead camshafts, 4 valves per cylinder overhead camshafts, 4 valves per cylinder; variable valve timing overhead camshafts, 4 valves per cylinder Ignition system: electronic direct “| electronic direct, eoil-on- plug electronic direct Fuel delivery: sequential multi-port fuel injection with electronic throttle control ‘sequential multi-port fuel injection with high-flow injectors and electronic throttle control Sequential multi-port fuel injection with high-flow injectors and electronic throttle control [Compression ratio: 10:1 10.4:1 95:1 fforsepower(np/kw@ | 148/110@ 5600 | 173/129@<200" | 205/152 @ 5000 frorave (b-t7 Nm @ 152/260 @ 420° 463/221 @ 4800" 200 / 230 @ 400 Recommended fuel: regular unleaded premium recommended but not required ‘premium recommended but not required fimum engine apsed (rpm): 6750 6800 6500 [Exhaust system: Slainiess steel with aluminized coating on the| muffler and tailpipe stainless steel with ‘aluminized coating on the| ‘muffler and tailpipe stainless steel with laluminized coating on the| mutfier and tailpipe FFnssione contol: dlose-coupled catalytic converters; Quick-Sync 24X ignition system; retumless fuel delivery system; fast-response O 2 sensor ‘lose-coupled catalytic converters; High Resolution 58X ignition system; returnless fuel delivery system; fast- response O 2 sensor ‘lose-coupled catalytic converters; High Resolution 58X ignition system; returless fuel delivery system; fast- [Estimated fuel economy ‘mpg city / hwy): manual: 25 734 automatic: 24 / 32 ‘manual: 25 / 34 automatic: 24/32 eee cee response O 2 sersor_| Page 7 2007 Chevrolet Cobalt Restoration Kit Transmission Hydra: Watie 4T4S-E Sspocdmanval, | speed automatic |g os meray, Type: frontawhea! drive (Ls, | woxerarve one | front-whool drive (SS LT, LTz, $8) eee | Supercharged) Gear ratios (1): Fist 3 2.95 36 Second: : 1.62 176 Thre 71.00 [ie Fourth 0.68 0.89) Fifth i 0.70 Reverse: a8 “3.47 Final rive rao: 3.631 4.05: Chassis/Suspension Front: independent sirut-type suspension with stabilizer bar Rear: ‘semi-independent torsion beam with stabilizer bar ‘Steering type: electric, power-assisted variable-speed rack-and-pinion ‘Steering ratio: 16.63:1 ‘Steering wheel tums, look-to-lock: S,LT, L1Zand SS); 3.98 (SS Supercharged) Turning circle, curb-to-curb (ft m): 37.47 11.4 (LS, LT, LTZ and $8); 40.7 / 12.4 (SS ‘Supercharged) Brakes Type: Power-assisted front disc, rear drum (LS, LT and LTZ); power- assisted 4-wheel discs (SS and SS Supercharged) Front rotor (diameter x thickness, in / mm): LS, LT and LTZ: 10.7 x .94 / 256 x 24; vented discs SS and SS Supercharged: 11.6 x 1.02 / 295 x 26; vented discs Rear (diameter x thickness in / mm): LS, LT and L1Zz: 0.57 42; drums SS and SS Supercharged : 10.6 x .55 / 270 x 14; solid discs Front total swept area (sqin / sq cm): LS, LT and LTZ: 47 / 303.17 SS and SS Supercharged: 63.9 / 408.3 Rear total swept area (sq in / sq om): LS, LT and LTZ: 45.2/ 292.07 SS and SS Supercharged: 43.48 / 280.55 Wheels/Tires 1S:15x6 LT: 15x6 Whee! size and type: furz4 16x6 SS: 17 x7 ‘SS Supercharged: 18 x7. LS: P195/60R15 touring LT: P195/60R15 touring Tires: LTZ: P205/55R16 touring ‘SS: P205/50R17 performance ‘SS Supercharged: P215/45ZR18 performance, W-raled_ Page 8 2007 Chevrolet Cobalt Restoration Kit Dimensions [Exterior ‘Sedan Coupe fneelbase (in mm): 708.37 2624 703372624 (Overall length (in mm 180.5 74584 180.3 / 4560 Overall with (in mm) 67.9 1725, 67.91 1725 werall height (in / mm): 87.1 1450. 85.7 1418.4 ont: §8.7 / 1452 Font: 57.11 1440.7 [frack (in mm rear: 58.1 / 1476 rear: 58.1/1476 Minimum ground clearance i | 5.36 /136.2 5.36 / 136.2 TS: 276077261 TS:27307 1230 . LT: 270 / 1267 LT: 2742 / 1244 [Curb weight (Ib / ka}: L7z:2008 11318 88: 2815/1277 SS: 2871/1302 SS Supercharged: 2025 /1327 eight distribution (% front/rear) 59/44 60/ 40 ; Sedan Coupe’ Anterlor Front Rear Front Rear Seating capacity 2 3 2 3 Head room (in / mi 355/979_| 37719584 | 387/984 | 9571 95.7 Leg room (in/ mm): 48 / 10627 | ~33:7/8526 | 42/ 1066.5 | 322/817 Shoulder room (in/ mmy_ 53/ 1345.8 | 61.4/13054 | 63/1346.5 | 49/12458 Hip room (in mm) 49.51 1257.1 | 49.6/1261.1 | 49.5/1257.1 | 46.1/1171.8 Capacities EPA passenger volume (cu ft): Coupe: 8372350 Sedan: 87.1 / 2469.3 EPA interior volume (cu fUlL): Coupe: 97/2747 nter Sedan: 101 /2863 Cargo volume (eu 13.9 Trailer towing maximum (B/kg) TS, UT, 11Zand SS: 10007 454 Fuel tank (gall): 13.2149 Bal: 5747 Engine oil (U/L): 2.4L: 514.7 2.0 SC: 6/56 2.21: 6.9/6.5 Cooling system (atlL): 24L: 7.417 2.0L SC: 9.25 / 8.75 (includes intercooler circuit) * Preliminary, pending certficaion. A new voluntary power and forquecertcaton procedure developed by the SAE Encino Test Code commites was approved March 31, 2005 This prosedure (2723) ensures far, accurate ratings fr horsepower and orque by along manufactures fo arity ther engines trough thir:party witness testing. GM was the fst auto manufacturer fo oegin sing the procedure and expects fo use i forall newly rated engines in the future Page 9 2007 Chevrolet Cobalt Restoration Kit Vehicle Identification Vehicle Identification Number (VIN) - iy . S The vehicle identification number (VIN) plate is the legal identifier of the vehicle. The VIN plate is located on the upper LH comer of the Instrument Panel and can be seen through the windshield from the outside of the vehicle: Position Definition Character Description i Couniry of Origin 1 United States | Manufacturer c General Motors 1 Chevrolet 3 Make | 3 ie z AK AL, Alf, AP Chevrolet LS, LT, SS, SSI 5 ce AJLAL AN Pontiac SE, GT. Two-Door Coupe (37) e Body Style 1 Four-Door Sedan (69) : [Adive (Manual) Belts WiDriver and Passenger y eesitalns Siem 2 Inflatable Restraint System - Frontal F RPO L61, 2.2L, L4, MFI 8 Engine Type P RPOLSJ, 2.01, MFI, 4 CYL, SC 3 RPO LES, 2.4L, L4, MFI a Check Digi = Check Digit 10 Mode! Year 7 2007 11 Piant Location T “Lordstown, OH, USA 72-17 _ [Plant Sequence Numiber = Plant Sequence Number | Page 10 2007 Chevrolet Cobalt Restoration Kit VIN Derivative All engines and transmissions are stamped or laser etched with a partial vehicle identification number (VIN), which was derived from the complete VIN. A VIN derivative contains the following nine positons: Position Definition Character Description 1 GM Division Identiier 2 chee 2 Pontiac 2 ‘Model Year 7 2007 3 ‘Assembly Plant 7 Lordstown, OF 4-9 | Piant Sequence Number = = ‘A VIN derivative can be used to determine if a vehicle contains the original engine or transmission, by matching the VIN derivative positions to their accompanying positions in the complete VIN: VIN Derivative Position 1 z 3 49 Equivalent VIN Position 3 10 1 2-17 Page 11 2007 Chevrolet Cobalt Restoration Kit Engine ID and VIN Derivative Location Identification can be made through the use of the Broadcast Code label on the engine front cover (1) and the use of the partial VIN etched on the oil filter bow! (2). Page 12 2007 Chevrolet Cobalt Restoration Kit

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