Cobalt 2006-2008, G5 2007

Intake Manifold

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the supercharger.
  4.  
  5. Remove the generator.
  6.  
  7. Drain the charged air cooling system.
  8.  
  9. Disconnect the charged air cooling system inlet and outlet hoses.
  10.  
  11. Remove the charged air coolant pump.
  12.  
  13. Remove the cooling fan assembly.
  14.  
  15. Remove the oil level indicator tube bolt.
  16.  
  17. Remove the electrical connector from the intake manifold.
  18.  
  19. Remove the coolant hoses from the intake manifold.
    NOTE
    Be sure to remove all fasteners before attempting to remove the intake manifold.



    Click image to see an enlarged view

    Fig. Intake manifold-2.0L engine

  20.  
  21. Remove the intake manifold nuts and bolts.
  22.  
  23. Remove the intake manifold.
    NOTE
    The intake manifold gasket is reusable. Only replace the gasket if damage has occurred.

  24.  
  25. Remove the intake manifold gasket.
  26.  

To install:

  1. Install the intake manifold gasket.
  2.  
  3. Install the intake manifold.
  4.  
  5. Install the intake manifold nuts and bolts. Tighten the intake manifold nuts and bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the coolant hoses to the intake manifold. Tighten the hose clamps to 13 ft. lbs. (17 Nm).
  8.  
  9. Connect the electrical connector to the intake manifold.
  10.  
  11. Install the oil level indicator tube and bolt. Tighten the oil level indicator tube bolt to 89 inch lbs. (10 Nm).
  12.  
  13. Reposition the A/C compressor and install the bolts. Tighten the bolts to 16 ft. lbs. (22 Nm).
  14.  
  15. Install the cooling fan assembly.
  16.  
  17. Install the charged air coolant pump.
  18.  
  19. Install the generator.
  20.  
  21. Connect the charged air cooling system inlet and outlet hoses.
  22.  
  23. Fill the charged air cooling system.
  24.  
  25. Install the supercharger.
  26.  

2.2L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the air cleaner outlet resonator.
  4.  
  5. Remove the throttle body.
  6.  
  7. Disconnect the Positive Crankcase Ventilation (PCV) hose.
  8.  
  9. Disconnect the purge solenoid tube.
  10.  
  11. Disconnect the brake booster hose.
  12.  
  13. Remove the oil level indicator tube bolt.
  14.  
  15. Remove the fuel rail.
  16.  
  17. Disconnect the knock sensor electrical connector.
  18.  
  19. Remove the knock sensor harness connector from the intake manifold.
  20.  
  21. Remove the intake manifold nuts and bolts.
  22.  
  23. Remove the intake manifold.
    NOTE
    The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

  24.  
  25. If applicable, remove the intake manifold gasket.

    Click image to see an enlarged view

    Fig. Intake manifold-2.2L engine

  26.  

To install:

  1. If applicable, install the intake manifold gasket.
  2.  
  3. Install the intake manifold.
  4.  
  5. Install the intake manifold nuts and bolts. Tighten the intake manifold nuts and bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the knock sensor harness connector to the intake manifold.
  8.  
  9. Connect the knock sensor electrical connector.
  10.  
  11. Install the fuel rail.
  12.  
  13. Install the throttle body. Tighten the throttle body attaching bolts to 89 inch lbs. (10 Nm).
  14.  
  15. Install the oil level indicator tube bolt. Tighten the oil level indicator tube bolt to 89 inch lbs. (10 Nm).
  16.  
  17. Connect the brake booster hose.
  18.  
  19. Connect the purge solenoid tube.
  20.  
  21. Connect the PCV hose.
  22.  
  23. Install the throttle body.
  24.  
  25. Install the air cleaner outlet resonator.
  26.  

 
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