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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 31 (ENGINE MECHANICAL)REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSINTAKE PLENUM REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2005 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing & Installing Throttle Body Assembly
    GM894807Courtesy of GENERAL MOTORS CORP.
  1. Install the throttle body gasket to the plenum.
  2. Install the throttle body to the plenum.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the throttle body nuts.

    Tighten:  Tighten the throttle body nut to 8 N.m (71 lb in).

    4. Fig 2: Removing & Installing Intake Plenum
    GM896435Courtesy of GENERAL MOTORS CORP.
  4. Attach the heater and vent hose to the throttle body.
  5. Install the intake plenum and intake plenum bolts. Finger tighten the bolts.
  6. Install the EGR pipe bolts.

    Tighten:  Tighten the EGR pipe bolts to 25 N.m (18 lb ft).

  7. Install the intake plenum bolts.

    Tighten:  Tighten the intake plenum bolts to 8 N.m (71 lb in).

    8. Fig 3: Removing & Installing Front Intake Manifold Runner
    GM896433Courtesy of GENERAL MOTORS CORP.
  8. Install the front manifold runner and tighten the clamps.
  9. Install the intake runner bolts.

    Tighten:  Tighten the intake manifold runner bolts to 8 N.m (71 lb in).

  10. Connect the negative battery cable.

    Tighten:  Tighten the battery terminal bolts to 17 N.m (13 lb ft).

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.