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

Removal Procedure

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.
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.
    Fig 1: Identifying Intake Manifold Vacuum Lines & Air Valve Solenoid Electrical Connectors
    GM2003695Courtesy of GENERAL MOTORS CORP.
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  2. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
  3. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  4. Disconnect the fuel feed line quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  5. Disconnect the charge air valve solenoid vacuum lines (1).
  6. Disconnect the charge air valve solenoid vacuum electrical connector (2).
    7. Fig 2: Locating EVAP Line Connector & MAP Sensor Electrical Connector
    GM2003725Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the evaporative emission (EVAP) electrical connector (1) from the EVAP purge solenoid.
  8. Disconnect the evaporative emission (EVAP) line quick connect fitting (2) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (3).
    10. Fig 3: View Of Brake Booster Vacuum Hose
    GM1825523Courtesy of GENERAL MOTORS CORP.
  10. Reposition the brake booster vacuum hose clamp at the intake manifold.
  11. Remove the brake booster hose from the intake manifold.
    12. Fig 4: Locating Knock Sensor Electrical Connector
    GM2031491Courtesy of GENERAL MOTORS CORP.
  12. Remove the knock sensor electrical connector (1) clip from the intake manifold brace.
    13. Fig 5: Identifying Knock Sensor Connector
    GM1825527Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator control (TAC) module.
  14. Remove the engine wiring harness clip (3) from the intake manifold brace.
    15. Fig 6: Identifying Surge Tank Air Bleed Hose
    GM2031935Courtesy of GENERAL MOTORS CORP.
  15. Reposition the surge tank air bleed hose clamp at the engine (1).
  16. Remove the surge tank air bleed hose (2) from the engine.
  17. Reposition the surge tank air bleed hose out of the way.
    18. Fig 7: Identifying Charge Air Bypass Valve Solenoid Assembly
    GM1825530Courtesy of GENERAL MOTORS CORP.
  18. Reposition the charge air bypass valve vacuum hose clamp at the intake manifold.
  19. Remove the charge air bypass valve vacuum hose from the intake manifold.
  20. Remove the charge air bypass valve solenoid bolts.
  21. Reposition the charge air bypass valve solenoid assembly out of the way.
    22. Fig 8: Identifying Fuel Feed Pipe & Bolts
    GM1825534Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the metal quick connect fitting from the fuel feed pip. Refer to Metal Collar Quick Connect Fitting Service .
  23. Disconnect the fuel feed pipe fitting from the fuel pump.
  24. Remove the fuel feed pipe bolts.
  25. Remove the fuel feed pipe.
  26. Inspect the fuel feed pipe nut for damaged threads.
  27. Inspect the fuel feed pipe sealing bail for damage or debris.
  28. Replace the fuel feed pipe if any damage is found.
  29. Remove the charge air bypass valve vacuum tank. Refer to Charge Air Bypass Valve Vacuum Tank Replacement .
    30. Fig 9: View Of Intake Manifold Brace
    GM1825528Courtesy of GENERAL MOTORS CORP.
  30. Remove the intake manifold brace bolt.
  31. Remove the intake manifold brace.
    32. Fig 10: Identifying Fuel Pump Bracket & Bolt
    GM2032106Courtesy of GENERAL MOTORS CORP.
  32. Remove the fuel pump bracket bolt (1).
    33. Fig 11: View Of Intake Manifold, Gasket & Bolts
    GM2032154Courtesy of GENERAL MOTORS CORP.
  33. Remove the intake manifold nuts (1) and bolts (2).
  34. Remove the intake manifold and place on a clean work surface.
    35. IMPORTANT: The intake manifold gasket is reusable. Only replace the gasket if damage has occurred.
  35. Remove the intake manifold gasket, if necessary.
    36. Fig 12: View Of EVAP Canister Purge Solenoid
    GM1825560Courtesy of GENERAL MOTORS CORP.
  36. If replacing the intake manifold perform the following steps, otherwise proceed to step 11 in the installation procedure.
  37. Remove the MAP sensor bolts (1).
  38. Remove the MAP sensor (2), ensure that the O-ring seal (3) is still attached on the sensor, if not remove the O-ring seal from the intake manifold.
  39. Remove the EVAP purge solenoid bolt (6).
  40. Remove the EVAP purge solenoid (5), ensure that the O-ring seal (4) is still attached on the sensor, if not remove the O-ring seal from the intake manifold.
    41. Fig 13: View Of Throttle Body
    GM1825561Courtesy of GENERAL MOTORS CORP.
  41. Turn the intake manifold up side down.
  42. Remove the throttle body bolts.
  43. Remove the throttle body and seal.
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