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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 428 (ENGINE MECHANICAL - 2.2L (L61))REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSINTAKE MANIFOLD 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 2006 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing/Installing Intake Manifold Gasket
    GM935002Courtesy of GENERAL MOTORS CORP.
  1. Remove the shop towel from the throttle body opening.
  2. Install the intake manifold gasket to manifold.
    3. Fig 2: Disconnecting/Connecting Brake Booster Hose
    GM947798Courtesy of GENERAL MOTORS CORP.
  3. Connect the brake booster hose to intake manifold.
  4. Install the intake manifold to cylinder head.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the intake manifold bolts and nuts.

    Tighten

    • Tighten the intake manifold-to-cylinder head bolts L61 to 10 N.m (89 lb in).
    • Tighten the intake manifold-to-cylinder head nuts L61 to 10 N.m (89 lb in).
    6. Fig 3: Identifying Oil Level Indicator Tube
    GM745887Courtesy of GENERAL MOTORS CORP.
  6. Install the oil level indicator tube assembly and bolt.

    Tighten:  Tighten the oil level indicator tube-to-intake manifold bolt L61 to 10 N.m (89 lb in).

    7. Fig 4: Removing/Installing ECM Assembly & Bolts
    GM947702Courtesy of GENERAL MOTORS CORP.
  7. Install the ECM assembly and bolts.
  8. Attach the electrical harness to the bottom of the intake manifold.
  9. Connect the electrical connector at the ECM, injector harness and MAP sensor.
    10. Fig 5: View Of Shop Towel Over The Throttle Body Opening
    GM951566Courtesy of GENERAL MOTORS CORP.
  10. Connect the purge hose.
  11. Remove the shop towel from the throttle body opening.
    12. Fig 6: Removing/Installing Throttle Body Gasket
    GM947783Courtesy of GENERAL MOTORS CORP.
  12. Install the new throttle body gasket.
  13. Install the throttle body assembly and bolts.

    Tighten:  Tighten the throttle body-to-intake manifold bolts L61 to 10 N.m (89 lb in).

    14. Fig 7: Disconnecting/Connecting Throttle Body Electrical Connector
    GM947518Courtesy of GENERAL MOTORS CORP.
  14. Connect the throttle body electrical connector.
    15. Fig 8: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  15. Position the outlet resonator/duct assembly into position.
  16. Connect the PCV fresh air vent hose assembly.
  17. Tighten the clamp at the throttle body assembly.
  18. Position the outlet resonator/duct assembly up with support bracket and install the push-pin.
    19. Fig 9: View Of Intake Air Temperature (IAT) Sensor Connector
    GM951542Courtesy of GENERAL MOTORS CORP.
  19. Tighten the clamp at the air cleaner assembly.
  20. Connect the intake air temperature (IAT) sensor connector.
RENDER: 1.0x

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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.