Pontiac 12587878 Manifold, Intake

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To begin with, for the removal of the intake manifold on all models, excluding 2.0L HHR engine, disconnect the negative battery terminal and remove any other components that might interfere such as turbocharger on turbocharged Cobalt/G5 models or air filter housing on HHR models. After that, remove the cover of the intake manifold, throttle body, and fuel rail. Furthermore, drain the coolant and remove electric coolant pump on 2.0L supercharged models and also take out supercharger if necessary. Disconnect vacuum hoses including brake hose, mark them for reassembly. Additionally, alternator and engine cooling fan/shroud assembly should also be removed in case of 2.0L supercharged models. Besides that set aside dipstick tube by removing dipstick tube mounting bolt without separating refrigerant lines from air conditioning compressor and also relocate wire harness of knock sensor near it. In addition to this follow these steps; first detach electrical connectors along harnesses from manifold, then loosen intake manifold nuts and bolts inside the cylinder head or heads releasing gases to lift entire air frame free yet while doing so avoid damaging other related parts such as valve stems which could result in catastrophic consequences such as seized piston rings due to insufficient oil flow through ventilation system caused by overheating during high RPM operation of motor vehicle; afterwards remove manifold mounting bolts with nuts finally lift up whole intake assembly away from engine bay area where it will rest until next step is taken place at end when new seals are fitted over each connecting rod cap screw compression ring surface under tightening torque specification so that seal's retaining groove can be effectively reduced until correct height reached thus sealing off each separate cylinder while allowing compression within combustion chamber during power strokes instead preventing blow-by escaping back out into atmosphere if not properly addressed causing lot extra pollution coming various sources too many men women children alike without even knowing what kind polluting substances were being released into air along highways around globe which ultimately kills innocent creatures like birds fish insects humans themselves through lung cancer occurring mainly due breathing all these harmful carcinogens emanating out from tailpipe where they were generated originally; finally reinstall gasket between cylinder head surfaces as necessary check oil level before starting engine again full synthetic lubricant having been used throughout assembly process ensuring adequate flow ensuring optimum performance even extreme off road conditions. Do not install the intake manifold without using a new gasket, and ensure clean mating surfaces between the manifold and cylinder head. When reinstalling it, use a new gasket and make sure that the mating surfaces are clean. Refill intercooler cooling system on 2.0L supercharged models, connect battery, check for vacuum or fuel leaks. For 2.0L HHR engine, remove air filter housing, charge air cooler pipe and disconnect electrical connectors and wiring harnesses after disconnecting negative battery terminal. Remove all the charge air bypass valve solenoid, relieve fuel system pressure and detach the fuel feed line from high-pressure fuel pump to avoid any fire accidents. It is also necessary to take off charge air bypass vacuum tank, intake manifold brace refrigerant line bolt as well as high-pressure fuel pump bracket bolt. Further remove the fasteners holding down the intake manifold and free it from its connection with the top of the cylinder head; then use a new gasket for installation making sure that there are no dirt on both surfaces; finally do everything backwards in order such as hooking up battery together with liquid or gas detectors connected against being heard leaking noises towards end.

After installation, reconnect the battery and check for vacuum and fuel leaks. For 2.0L supercharged models, refill the intercooler cooling system and ensure there are no leaks.