Chevrolet Cobalt Service & Repair Manual: Intake Manifold Gasket R&R

1. Remove the intake manifold cover.
2. Remove the air cleaner outlet duct.
3. Disconnect the engine harness electrical connector (1) from the throttle actuator control (TAC), Fig. 1.
4. Disconnect the engine harness electrical connector (2) from the fuel injector harness, Fig. 1.
5. Disconnect the engine harness electrical connector from the manifold absolute pressure (MAP) sensor.
6. Disconnect the engine harness clips (1 and 3) from the intake manifold, Fig. 2.
7. Disconnect the engine harness clip (2) from the oil level indicator tube, Fig. 2.
8. Disconnect the fuel injector electrical connector clip from the intake manifold.
9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold, Fig. 3.
10. Remove the vacuum brake booster hose from the intake manifold.
11. Remove the throttle body bolts, Fig. 4.
12. Remove the throttle body and seal.
13. Remove and inspect the throttle body seal.
14. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid.
15. Remove the oil level indicator tube.
16. Remove the fuel rail.
17. Remove the intake manifold lower bolts (1), Fig. 5.
18. Remove the intake manifold upper bolt and nuts.
19. Remove the intake manifold.
20. Remove and inspect the intake manifold gasket.
21. Reverse procedure to install, noting the following:
  a. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
  b. Torque intake manifold lower bolts to 89 inch lbs.
  c. Torque fuel rail bolts to 89 inch lbs.
  d. Torque oil level indicator bolt to 89 inch lbs.
  e. Torque throttle body bolts to 89 inch lbs.
  f. Torque air cleaner and throttle body clamps to 44 inch lbs.
  g. Torque throttle body bolts to 89 inch lbs.

Fig. 1 Engine and fuel injector harness

Fig. 2 Engine harness and intake manifold

Fig. 3 Vacuum brake booster hose replacement

Fig. 4 Throttle body replacement

Fig. 5 Intake manifold replacement

    Intake Manifold Bolts Re-Torque
    Refer to Fig. 1 when performing the following procedure. 1. Install the intake manifold bolts and nuts finger tighten. 2. ...

    Intake Manifold, Replace
    Removal 1. Remove air inlet duct and resonator. 2. Disconnect IAC, TPS and MAP sensor. 3. Disconnect EVAP and PCV ...

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