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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Mechanical - 2.4L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View of intake manifold, upper bolts and nuts
    GM1656110Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
  2. Install the intake manifold.
  3. Install the intake manifold upper bolt and nuts.
    4. Fig 2: Identifying Intake Manifold Lower Bolts
    GM1623769Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  4. Install the intake manifold lower bolts.

    Tighten:  Tighten the bolts/nuts to 10 N.m (89 lb in).

    5. Fig 3: Identifying EVAP Canister Purge Valve Tube
    GM1623766Courtesy of GENERAL MOTORS CORP.
  5. Install the fuel rail. Refer to Fuel Rail Assembly Replacement .
  6. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  7. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    8. Fig 4: Identifying Throttle Body
    GM1628032Courtesy of GENERAL MOTORS CORP.
  8. Install a NEW throttle body seal if necessary, otherwise install the old seal.
  9. Position the throttle body.
  10. Install the throttle body bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    11. Fig 5: View of vacuum brake booster hose clamp
    GM1656109Courtesy of GENERAL MOTORS CORP.
  11. Install the vacuum brake booster hose to the intake manifold.
  12. Position the vacuum brake booster hose clamp (2) at the intake manifold.
    13. Fig 6: View of engine harness clips
    GM1656100Courtesy of GENERAL MOTORS CORP.
  13. Connect the engine harness clips (1 and 3) to the intake manifold.
  14. Connect the engine harness clip (2) to the oil level indicator tube.
  15. Connect the fuel injector electrical connector clip to the intake manifold.
    16. Fig 7: Identifying Engine Harness Electrical Connector
    GM1647528Courtesy of GENERAL MOTORS CORP.
  16. Connect the engine harness electrical connector (2) to the fuel injector harness.
  17. Connect the engine harness electrical connector to the MAP sensor.
  18. Connect the engine harness electrical connector (1) to the TAC.
  19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  20. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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