Pontiac 12608305 Manifold Assembly, 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.

Before removing the upper intake manifold and spacer, depress the fuel pressure, if the lower intake manifold is to be removed as well. Let the cable on the negative terminal of the battery loose, and then remove the breather hose as well as the air intake duct. Remove the vacuum hoses and other joineries that is connected to the throttle body then remove the throttle body. Then, unbolt the brake booster hose and the PCV hoses from the intake manifold and remove the interfering engine harness connectors that are to be refitted and tag them accordingly. Take out the air outlet duct bracket and the intake manifold cover. The bolts and nuts are to be removed in the reverse of the tightening sequence, which will free the upper intake manifold from the engine and spacer and gaskets can also be removed. For the installation, remove the old gasket from the studs of the lower manifold and clean the mounting surfaces of both manifolds, This is followed by putting on a new gasket over the studs on the lower manifold before putting on the spacer then followed by the upper intake manifold where all the fasteners have to be tightened in a cycle in the manner described above while using the specified torque. Engine intake manifold cover should be installed with a new gasket; the bolts should be tightened taking into account the recommended sequence. Connect the battery, look at the coolant level and if none add it. For the lower intake manifolds, first the upper intake manifold and spacer plate has to be removed, next fuel rails and injectors. Remove the two lower intake manifold sections from the cylinder heads with care so as not to mar the gasket surfaces. Scrape the layers of gasket material off and clean the flanges of both manifolds and cylinder heads; then apply new gaskets and place the lower manifolds across the dowel pins. Tighten it slowly towards the end in order to avoid the warping of the fasteners and then fit the upper intake manifold. Last but not the least, one can check the coolant level and rev up the engine to ensure there is no leakage.

To remove the intake manifold, you should remove the intake manifold mounting bolts and nuts, then lift the manifold from the engine compartment.

After disconnecting the battery, you need to remove the intake air duct assembly and throttle body, then take out the mounting bolts from the PCM and move it aside.

To remove the intake manifold, you should remove the intake manifold mounting bolts and nuts, then lift the manifold from the engine compartment.

Disconnect the fuel line at the quick-connect fitting.

They should be tightened to 10 ft./lbs.