How to replace the starter on a GM 2.2L Ecotec engine in Cobalt, Cavalier, HHR, Malibu and more

     The starter on GM's 2.2L Ecotec engine is more difficult than most to remove, owing to a hard-to- access upper mounting bolt. This post applies to many small GM cars such as the Cavalier, Cobalt, HHR, Malibu, Alero, Grand Am, Sunfire, Saturn L series and Ion and some Opel and Vauxhall cars.  I posted this tutorial with the hope of  helping the home mechanic in performing this frustrating job.
This post features a 2006 Chevy Cobalt.

                                                        The job at a glance

• Tools: floor or other jack, jack stands or wood supports, 8mm deepwell socket, 13mm socket (1/4" drive) 15mm socket and 3/8 or 1/2" ratchet, 3 and 6" extension bar 
• Materials: none
• Parts: Starter  
• Cost of parts: Starter $85- $130
• Time: 1-2 hours

Removal

1) Remove the large plastic engine cover to get a better view of the position of the upper bolt. Pull the cover free of the two ball headed posts, one at the extreme left of the cover and the other near the dipstick at the lower front. 

2) Jack up the front of the car. I used a floor jack on the front tubular cross member, with a  three foot long two by four to spread the weight of the car more evenly. Set it down on some jack stands or wood supports. 

3) Disconnect the battery with a 10mm wrench or socket. It is in the trunk. 

4) Unwire the starter. There are two connections to unwire. The small 8mm nut is the solenoid control signal and the larger 13mm uppermost is the battery plus connection.

Remove these two nuts to unwire. GM left the starter studs unprotected from the elements. 

5) Break the lower 15mm mounting bolt loose.This is the easy one. The upper bolt will more than make up for it though. 

6) Break the upper 15mm mounting bolt loose and then remove. This is the toughie. Use a three or six inch extension bar and a deep well socket fed from underneath. To find the bolt, have the socket and extension close to the engine and just probe until it seats on the bolt head. This may take a try or three. It may help to check the fit from above as the bolt head is just visable from up there in just the right light and angle.

At last, we're on the bolt. Note position of tools relative to starter and engine. 

7) Completely remove the lower starter mounting bolt.

8) Remove the starter. Mine was corroded in place. I used a large screwdriver wedged between the right end of the solenoid and the transmission to force it apart from the transmission.

There's the hole for the upper bolt

Installation

1) Affix the upper starter mounting bolt to the deep well socket. I used a piece of paperboard around the bolt head and then jammed the socket on it. This serves to hold the bolt to the socket so they don't fall apart during install. That would be very frustrating. Use a three inch extension with the deep well. Hold the bolt and tools in the upper mounting hole in the new starter as you place it in position. 

Start the upper bolt first if possible or at least hold it in place until the lower bolt is turned in to hold the starter up.

The socket and bolt are like one part going in

2) Tighten both bolts. Precision torque is not critical on a starter. 

3) Rewire the electrical connections. 

4) Remove the stands and lower the car. 

5) Install the engine cover. 

6) Connect the battery.

7) Test.