HHR 2006-2008

Intake Manifold

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Removal & Installation



2.0L Engine

WARNING
Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold is made of a composite plastic and can be damaged if it is removed when the engine is hot.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold cover
  4.  
  5. Remove the oil level indicator tube.
  6.  
  7. Disconnect the fuel feed line quick connect fitting from the fuel rail.
  8.  
  9. Disconnect the Evaporative Emission (EVAP) line quick connect fitting from the EVAP purge solenoid.
  10.  
  11. Reposition the brake booster vacuum hose clamp at the intake manifold.
  12.  
  13. Remove the brake booster hose from the intake manifold.
  14.  
  15. Remove the knock sensor electrical connector (1) clip from the intake manifold brace.
  16.  
  17. Remove the knock sensor electrical connector clip from the oil level indicator tube bracket.
  18.  
  19. Disconnect the engine wiring harness electrical connector from the EVAP canister purge solenoid
  20.  
  21. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
  22.  
  23. Disconnect the engine wiring harness electrical connector from the charge air bypass vale solenoid.
  24.  
  25. Disconnect the engine wiring harness electrical connector from the Throttle Actuator Control (TAC) module.
  26.  
  27. Remove the engine wiring harness clip from the intake manifold brace
  28.  
  29. Reposition the surge tank air bleed hose clamp at the engine.
  30.  
  31. Remove the surge tank air bleed hose from the engine.
  32.  
  33. Remove the surge tank air bleed hose clip from the surge tank bracket.
  34.  
  35. Reposition the surge tank air bleed hose out of the way.
  36.  
  37. Reposition the charge air bypass valve vacuum hose clamp at the intake manifold.
  38.  
  39. Remove the charge air bypass valve vacuum hose from the intake manifold.
  40.  
  41. Remove the charge air bypass valve solenoid bolts.
  42.  
  43. Reposition the charge air bypass valve solenoid assembly out of the way.
  44.  
  45. Remove the surge tank bracket bolt and stud.
  46.  
  47. Remove the surge tank bracket.
  48.  
  49. Remove the surge tank hose retainer and hose from the surge tank bracket.
  50.  
  51. Disconnect the metal quick connect fitting from the fuel feed pipe.
  52.  
  53. Disconnect the fuel feed pipe fitting from the fuel pump.
  54.  
  55. Remove the fuel feed pipe bolts.
  56.  
  57. Remove the fuel feed pipe.
  58.  
  59. Inspect the fuel feed pipe nut for damaged threads.
  60.  
  61. Inspect the fuel feed pipe sealing bail for damage or debris.
  62.  
  63. Replace the fuel feed pipe if any damage is found.
  64.  
  65. Unbolt and reposition the power brake booster pump
  66.  
  67. Remove the intake manifold brace bolt.
  68.  
  69. Remove the intake manifold brace.
  70.  
  71. Remove the intake manifold bolts and nuts.
  72.  
  73. Remove the intake manifold and place on a clean work surface.
    NOTE
    The intake manifold gasket is reusable. Only replace the gasket if damage has occurred.

  74.  
  75. Remove the intake manifold gasket, if necessary

    Click image to see an enlarged view

    Fig. Intake manifold

  76.  

To install:

  1. Install new intake manifold gasket, if necessary.
  2.  
  3. Install the intake manifold to the studs.
  4.  
  5. Install the intake manifold bolts and nuts, tighten to 16 ft. lbs.(22 Nm).
  6.  
  7. Install the intake manifold brace.
  8.  
  9. Loosely install the intake manifold brace bolt.
  10.  
  11. Position and install the power brake booster pump.
  12.  
  13. Tighten the intake manifold brace bolt to 16 ft. lbs.(22 Nm).
  14.  
  15. Lubricate the high pressure fuel pump fuel feed pipe connection threads with silicon free engine oil.
  16.  
  17. Place the fuel feed pipe on top of the intake manifold.
  18.  
  19. Connect the fuel feed pipe fitting to the high pressure fuel pump.
  20.  
  21. Install the fuel feed pipe bolts.
    1. Tighten the bolts to 89 inch. lbs. (10 Nm).
    2.  
    3. Tighten the fittings to 22 ft. lbs. (30 Nm).
    4.  

  22.  
  23. Connect the metal quick connect fitting to the fuel feed pipe.
  24.  
  25. Position the surge tank bracket to the intake manifold.
  26.  
  27. Install the surge tank bracket bolt and stud. Tighten the bolt and stud to 80 inch. lbs. (9 Nm).
  28.  
  29. Install the surge tank hose retainer and hose to the surge tank bracket.
  30.  
  31. Position the charge air bypass valve solenoid assembly to the intake manifold.
  32.  
  33. Install the charge air bypass valve solenoid bolts and tighten to 89 inch. lbs. (10 Nm).
  34.  
  35. Install the charge air bypass valve vacuum hose to the intake manifold.
  36.  
  37. Position the charge air bypass valve vacuum hose clamp at the intake manifold.
  38.  
  39. Position the surge tank air bleed hose to the engine.
  40.  
  41. Install the surge tank air bleed hose to the engine.
  42.  
  43. Position the surge tank air bleed hose clamp at the engine.
  44.  
  45. Install the surge tank air bleed hose clip to the surge tank bracket.
  46.  
  47. Connect the engine wiring harness electrical connector to the TAC module.
  48.  
  49. Install the engine wiring harness clip to the intake manifold brace.
  50.  
  51. Connect the engine wiring harness electrical connector to the charge air bypass vale solenoid
  52.  
  53. Connect the engine wiring harness electrical connector to the MAP sensor.
  54.  
  55. Connect the engine wiring harness electrical connector to the EVAP canister purge solenoid.
  56.  
  57. Install the knock sensor electrical connector clip to the intake manifold brace.
  58.  
  59. Install the knock sensor electrical connector clip to the oil level indicator tube bracket.
  60.  
  61. Install the brake booster hose to the intake manifold.
  62.  
  63. Position the brake booster vacuum hose clamp at the intake manifold.
  64.  
  65. Connect the EVAP line quick connect fitting to the EVAP purge solenoid.
  66.  
  67. Connect the fuel feed line quick connect fitting from the fuel rail.
  68.  
  69. Install the oil level indicator tube.
  70.  
  71. Install the intake manifold cover.
  72.  

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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