2005 Chevrolet Cobalt Service and Repair Manual

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Factory-Grade Data

2005 Chevrolet Cobalt service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Sedan 4-Door
  • LS Coupe 2-Door
  • SS Coupe 2-Door
  • LT Sedan 4-Door
  • LS Sedan 4-Door
  • Base Coupe 2-Door
  • LT Coupe 2-Door

Engines covered

  • 2.2L 2198CC 134Cu. In. l4 GAS DOHC Naturally Aspirated
  • 2.0L 122Cu. In. l4 GAS DOHC Supercharged

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2005 Chevrolet Cobalt Recalls & Complaints

NHTSA #04V56000022/11/2004Component: EXTERIOR LIGHTING:HEADLIGHTS

CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE BULB S

Consequence

THE BULB SHIELD CAN LOOSEN OR BREAK BECAUSE OF VIBRATION. IF THIS OCCURRED ON A HEADLAMP

Remedy

DEALERS WILL INSTALL TWO NEW HEADLAMP ASSEMBLIES. THE RECALL BEGAN ON NOVEMBER 17, 2004.

NHTSA #07V01400018/01/2007Component: STRUCTURE

CERTAIN PASSENGER VEHICLES NOT EQUIPPED WITH OPTIONAL ROOF-MOUNTED SIDE IMPACT AIR BAGS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 201, 'OCCU

Consequence

IN A CRASH, HEAD IMPACT PROTECTION MAY BE INADEQUATE.

Remedy

DEALERS WILL INSTALL ENERGY ABSORBING PLASTIC TO THE HEADLINER TRIM TO REDUCE THE SEVERITY

NHTSA #14V04700010/02/2014Component: AIR BAGS

This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition k

Consequence

If the key is not in the run position, the air bags may not deploy if the vehicle is invol

Remedy

GM will notify owners, and dealers will replace the ignition switch, free of charge. An i

NHTSA #10V07300003/03/2010Component: STEERING:ELECTRIC POWER ASSIST SYSTEM

GENERAL MOTORS IS RECALLING CERTAIN MODEL YEAR 2005-2010 CHEVROLET COBALT AND MODEL YEAR 2007-2010 PONTIAC G5 VEHICLES EQUIPPED WITH ELECTRIC POWER STEERING. THE DRIVER MAY EXPERI

Consequence

IF POWER STEERING ASSIST IS LOST, IT WOULD REQUIRE GREATER DRIVER EFFORT AT LOW VEHICLE SP

Remedy

DEALERS WILL REPLACE THE ELECTRIC POWER STEERING MOTOR FREE OF CHARGE. OWNERS ARE BEING N

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11019074

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019073

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019072

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11014455

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the

TSB #11011782

This Preliminary Information communication provides information to the technician about the use of J-35616-64B terminal test probe, replacement terminals, and terminated leads. The J-35616-64B is the latest test probe released for checking

TSB #11009156

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and

TSB #11008956

This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. and Canada Dealers Only).

Showing the 8 most recent of 324 technical service bulletins on file with NHTSA.

20080220Component: STEERINGCrash reportedFire reported2 injured1 fatalities

EVENTS LEADING UP TO COMPLAINT OF '05 CHEVROLET COBALT STEERING PROBLEMS: THE COBALT WAS UNDER WARRANTY & GM ROAD SIDE ASSISTANCE WAS CALL FOR EACH FAILURES. 3 TIMES THE POWER S

20060111Component: STEERING:HYDRAULIC POWER ASSIST SYSTEMCrash reportedFire reported1 injured

DT*: THE CONTACT STATED WHILE DRIVING THE POWER STEERING FAILED. THE STEERING WHEEL WAS VERY HARD TO TURN. AFTER THE VEHICLE WAS PARKED THE POWER STEERING FLUID WAS CHECKED. THE

20140218Component: STEERINGCrash reportedFire reported1 fatalities

ON JANUARY 10TH, 2010 OUR DAUGHTER [XXX] 21 YRS. OLD WAS KILLED IN A CAR ACCIDENT. WE RECEIVED A RECALL NOTICE FROM GM IN APRIL 2010 ON THE CAR A 2005 CHEVY COBALT FOR POWER

20140218Component: ELECTRICAL SYSTEMCrash reportedFire reported1 fatalities

ON JANUARY 10TH, 2010 OUR DAUGHTER [XXX] 21 YRS. OLD WAS KILLED IN A CAR ACCIDENT. WE RECEIVED A RECALL NOTICE FROM GM IN APRIL 2010 ON THE CAR A 2005 CHEVY COBALT FOR POWER

Showing the 4 most serious of 2231 complaints filed with NHTSA.

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