Chevrolet 12587878 Manifold, Intake

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For the removal of the intake manifold on all models (except the 2.0L HHR engine), begin by disconnecting the negative battery terminal and removing any components that might interfere, such as the turbocharger on turbocharged Cobalt/G5 models or the air filter housing on HHR models. Next, remove the intake manifold cover, throttle body, and fuel rail. Disconnect electrical connectors and detach wiring harnesses from the manifold, drain the coolant and remove the electric coolant pump on 2.0L supercharged models, and remove the supercharger if applicable. Disconnect vacuum hoses, including the brake hose, and mark them for reassembly. On 2.0L supercharged models, also remove the alternator and engine cooling fan/shroud assembly. Position the air conditioning compressor aside without disconnecting the refrigerant lines, remove the dipstick tube mounting bolt, and set aside the dipstick and knock sensor wiring harness. Then, remove the intake manifold mounting bolts and nuts and lift the manifold from the engine compartment. For installation, use a new gasket if needed, ensuring clean mating surfaces between the manifold and cylinder head, and follow the reverse steps of removal. Refill the intercooler cooling system for 2.0L supercharged models, reconnect the battery, and check for vacuum or fuel leaks. For the 2.0L HHR engine, disconnect the negative battery terminal, remove the air filter housing and charge air cooler pipe, and disconnect electrical connectors and wiring harnesses. Detach vacuum hoses, including the brake booster hose, and mark them. Remove the charge air bypass valve solenoid, relieve fuel system pressure, and detach the fuel feed line from the high-pressure fuel pump. Remove the charge air bypass vacuum tank, intake manifold brace, refrigerant line bolt, and high-pressure fuel pump bracket bolt. Then, remove the intake manifold mounting fasteners and detach the manifold from the cylinder head. For installation, use a new gasket and ensure clean mating surfaces. Follow the reverse steps of removal, reconnect the battery, and check for vacuum and fuel leaks.

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.