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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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying Engine Harness Electrical Connector
    GM1647528Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Disconnect the engine harness electrical connector (1) from the throttle actuator control (TAC).
  4. Disconnect the engine harness electrical connector (2) from the fuel injector harness.
  5. Disconnect the engine harness electrical connector from the manifold absolute pressure (MAP) sensor.
    6. Fig 2: View of engine harness clips
    GM1656100Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the engine harness clips (1 and 3) from the intake manifold.
  7. Disconnect the engine harness clip (2) from the oil level indicator tube.
  8. Disconnect the fuel injector electrical connector clip from the intake manifold.
    9. Fig 3: View of Vacuum brake booster hose clamp
    GM1656109Courtesy of GENERAL MOTORS CORP.
  9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
  10. Remove the vacuum brake booster hose from the intake manifold.
    11. Fig 4: Identifying Throttle Body
    GM1628032Courtesy of GENERAL MOTORS CORP.
  11. Remove the throttle body bolts.
    12. IMPORTANT: The throttle body seal is reusable, only replace the seal if damaged.
  12. Remove the throttle body and seal.
  13. Remove and inspect the throttle body seal.
    14. Fig 5: Identifying EVAP Canister Purge Valve Tube
    GM1623766Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  15. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  16. Remove the fuel rail. Refer to Fuel Rail Assembly Replacement .
    17. Fig 6: Identifying Intake Manifold Lower Bolts
    GM1623769Courtesy of GENERAL MOTORS CORP.
  17. Remove the intake manifold lower bolts.
    18. Fig 7: View of intake manifold, upper bolts and nuts
    GM1656110Courtesy of GENERAL MOTORS CORP.
  18. Remove the intake manifold upper bolt and nuts.
  19. Remove the intake manifold.
    20. IMPORTANT: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.
  20. Remove and inspect the intake manifold gasket.
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