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HOMESERVICE MANUALSCHEVROLET2008HHR LT, 2.4 P, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 169 (INTAKE MANIFOLD AND EXHAUST SYSTEM)INTAKE MANIFOLD REMOVAL AND INSTALLATIONINSTALLATION
2008 Chevrolet HHR LT, 2.4 P, Automatic

Intake Manifold Removal and Installation: Installation

2008 Chevrolet HHR LT, 2.4 P, AutomaticSECTION Installation
WARNING: This page is about a different car, the 2011 Honda Insight and 2010 Honda Insight. However, it is still accessible from the selected car via links, so may be relevant.
  1. Reassemble the intake manifold.
    NOTE: Refer to the Exploded View if needed during this procedure.
  2. Install the EGR plate (A) with a new gasket (B).
    Fig 1: EGR Plate And Intake Manifold With Torque Specifications
    G06429073Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Install the intake manifold (C) with new gaskets (D), and tighten the bolts/nuts in a crisscross pattern in three steps, beginning with the inner bolt.
  4. Loosen the intake manifold bracket mounting bolt (A). Tighten the mounting bolts (B), then tighten the mounting bolt (A).
    Fig 2: Intake Manifold Bracket Mounting Bolt With Torque Specifications
    G06429074Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Install the throttle body (A) with a new gasket (B).
    Fig 3: Throttle Body With Gasket With Torque Specifications
    G06429075Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Install the dipstick.
  7. Install the PCV hose (A) and the harness holder (B).
    Fig 4: Installing PCV Hose And Harness Holder
    G06429076Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Install the EVAP canister purge hose (A).
    Fig 5: Identifying EVAP Canister Purge Hose
    G06429077Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Install the brake booster vacuum hose (A) and the harness clamp (B).
    Fig 6: Identifying Brake Booster Vacuum Hose And Harness Clamp
    G06429078Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Install the engine wire harness connectors and the wire harness clamps to the intake manifold.
    • Throttle actuator connector
    • MAP sensor connector
    • EGR valve connector
    • EVAP canister purge valve connector
  11. Install the air cleaner (see AIR CLEANER REMOVAL/INSTALLATION ).
  12. Install the engine cover.
    Fig 7: Identifying Engine Cover
    G06429079Courtesy of AMERICAN HONDA MOTOR CO., INC.
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.