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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 790 (Engine Mechanical - 2.0L) >> Repair Instructions - Off Vehicle >> Intake Manifold Removal

Intake Manifold Removal

WARNING: This page is about a different car, the 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of AIR Bypass Tube Assembly
    GM2048166Courtesy of GENERAL MOTORS CORP.
    NOTE: 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. If the engine is equipped with a charger AIR bypass valve tank assembly, complete the following procedure:
      IMPORTANT: The charger AIR bypass tube assembly connected from the charger AIR bypass valve solenoid to the charger AIR bypass valve tank assembly is permanently attached to the tank assembly. Do not attempt to disconnect the charger AIR bypass tube assembly at the charger AIR bypass valve tank assembly.
    1. Disconnect the charger AIR bypass tube with the retaining clip from the charger AIR bypass valve tank assembly.
    2. Disconnect the remaining charger AIR bypass tubes at the turbocharger and vehicle.
    3. Remove the charger AIR bypass valve solenoid bolts.
    4. Remove the charger AIR bypass valve solenoid.
    2. Fig 2: Identifying AIR Bypass Valve Tank Assembly
    GM2045492Courtesy of GENERAL MOTORS CORP.
  2. If the engine is equipped with a charger AIR bypass valve tank assembly, complete the following procedure:
    1. Disconnect the charger AIR bypass tube assembly from the intake manifold.
    2. Remove the charger AIR bypass valve tank assembly nut.
      3. IMPORTANT: The charger AIR bypass bolt is captured on the bracket and should not be removed from the bracket. Loosen the bolt only until it is no longer attached to the block when removing the charger AIR bypass valve tank assembly.
    3. Loosen the charger AIR bypass valve tank assembly bolt.
    4. Remove the charger AIR bypass valve tank assembly.
    3. Fig 3: Bypass Valve Solenoid Hoses
    GM1769657Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
  3. If the engine is not equipped with a charger AIR bypass valve tank assembly, complete the following procedure:
    1. Disconnect the charger AIR bypass valve solenoid tubes.
    2. Remove the charger AIR bypass valve solenoid bolts.
    3. Remove the charger AIR bypass valve solenoid with tubes.
    4. Fig 4: Identifying Fuel Feed Line
    GM1769663Courtesy of GENERAL MOTORS CORP.
    CAUTION: Fuel that flows out at high pressure can cause serious injury to the skin and eyes. ALWAYS depressurize the fuel system before removing components that are under high fuel pressure.
  4. Loosen and disconnect the fuel feed line tube nut.
  5. Remove the fuel feed line bolts.
  6. Remove the fuel feed line.
  7. Inspect the fuel feed line nut for damaged threads.
  8. Inspect the fuel feed line sealing bail for damage or debris.
  9. Replace the fuel feed line if any damage is found.
    10. Fig 5: View Of High Pressure Fuel Pump Cover
    GM1769666Courtesy of GENERAL MOTORS CORP.
  10. Remove the high pressure fuel pump cover bolts.
  11. Remove the high pressure fuel pump cover.
  12. Remove the high pressure fuel pump noise insulator.
    13. Fig 6: View Of Throttle Body & Bolts
    GM1769706Courtesy of GENERAL MOTORS CORP.
  13. Remove the throttle body bolts.
  14. Remove the throttle body.
    15. Fig 7: Identifying Intake Manifold Brace
    GM1769715Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the rear knock sensor from the intake manifold brace.
  16. Remove the intake manifold brace bolt.
  17. Remove the intake manifold brace.
    18. Fig 8: View Of Intake Manifold
    GM1769718Courtesy of GENERAL MOTORS CORP.
  18. Remove the intake manifold bolts and nuts.
  19. Remove the intake manifold.
  20. Remove the intake manifold gasket.
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