Oldsmobile 12608305 Manifold Assembly, Intake

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.

Disconnect the cable from the negative battery terminal. Remove the intake air duct and the duct support bracket from the top of the engine. Relieve the fuel system pressure and disconnect the fuel line at the quick-connect fitting. Disconnect the wiring from the intake manifold and secure it out of the way. Disconnect the EVAP purge solenoid and its hoses from the back of the manifold, as well as the brake vacuum hose. Label and disconnect the other wiring from the intake manifold, positioning the harnesses aside, and disconnect the PCV hose. Remove the throttle body coolant hose bracket bolts, then remove the throttle body mounting bolts and move the throttle body to the side while leaving the coolant hoses attached. Remove the five upper manifold bolts and a lower intake manifold bolt near the throttle body, then lift off the upper section of the intake manifold. Remove the bolts from the lower intake manifold adapter plate in reverse order of tightening, then take off the lower intake manifold plate. Clean all sealing surfaces thoroughly and replace any damaged lower intake manifold O-rings, using thread locking compound on the lower intake manifold bolts. The remaining installation steps are the reverse of removal, ensuring all fasteners are tightened in the correct sequence to the specified torque values. Finally, reconnect the battery, start the engine, and check carefully for leaks.

Before that intake manifold can be removed, the negative cable on the battery must be disconnected. Then, you should turn the intake air duct assembly and the throttle body around and pull them out, as for the PCM, you have to unbolt it and swivel it aside. Remove the fuel injector wire harness by booty clamp from the intake manifold and the wire harness from the MAP sensor. Lift the car off the ground and place it on jack-stands disconnecting the harness from the bottom of the intake manifold and lowering the car if necessary for easier access. First take out the dipstick tube mounting bolt and move the dipstick aside and then unbolt and take off the wiring bolt present in the lower part of the manifold and the EVAP purge tube. Any obvious vacuum hoses which may be connected to the manifold should be disconnected and the position remembered just in case their connection is needed later. It is necessary to withdraw the intake manifold, undoing the bolts and nuts on the manifold surface and on the engine block, to unfasten the brake vacuum hose, having pressed on the tab on it, and to lift the manifold out of the engine compartment. For uninstallation, the intake manifold gaskets have to be removed, and with more often use, they will require replacement; the surfaces of the manifold or the cylinder head should also be cleaned. Position the manifold over the studs on the cylinder head, screw in the bolts and nuts and tighten them just enough using your hands before actually using a torque wrench on the central bolts before proceeding to either side. The rest of the installation is the process reversed from removal. Last but not the least, join the battery and start the engine and look for the Vacuum, Coolant and fuel leaks.

For installation, use a new gasket if needed, ensuring clean mating surfaces between the manifold and cylinder head. Follow the reverse steps of removal.

For installation, use a new gasket if needed, ensuring clean mating surfaces between the manifold and cylinder head. Follow the reverse steps of removal.

First, relieve the fuel pressure if the lower intake manifold will also be removed.

They should be tightened to 10 ft./lbs.