OEM 2009 Chevrolet HHR Intake Manifold

2009 Chevrolet HHR Intake Manifold Parts Questions & Experts Answers

• Q: How to replace the intake manifold on 2009 Chevrolet HHR?

  A: Intake Manifold replacement starts by removing the radiator air baffle and deflector and continuing with the air cleaner assembly followed by charge air cooler inlet pipe and oil level indicator tube. Disconnect the quick connect fuel line fitting from the Fuel Rail combined with charge air valve solenoid vacuum and electrical lines and charge air bypass valve and evap purge solenoid's vacuum lines and evap electrical connector. Use a screwdriver to remove the evap hose from its clip before disconnecting the evaporative emission line quick connect fitting from the evap purge solenoid. Manifold absolute pressure sensor electrical connector gets disconnected while a brake booster vacuum hose clamp moves position then a knock sensor electrical connector clip gets removed from oil level indicator tube bracket. First disconnect the engine wiring harness electrical connector from the throttle actuator control module then remove the brake booster hose from the Intake Manifold. Uninstall the charge air bypass valve solenoid assembly while removing the fuel feed pipe fitting from the Fuel Pump followed by unfastening the fuel feed pipe bolts and removing the pipe for inspection of possible damage. Detach the charge air bypass vacuum tank from the Intake Manifold brace while removing its wiring harness connector alongside the charge air bypass vacuum tank bolt and charging air bypass vacuum tank brace. Begin by removing two fasteners associated with the air Intake Manifold brace and then move onto unfastening the high pressure Fuel Pump bracket while also removing the a/c line bracket. Use a wrench and socket to eliminate the Intake Manifold bolts and nuts before removing the part and discarding the gasket. Before installing a new Intake Manifold you should remove the MAP Sensor and evap purge solenoid and check that o-ring seals remain intact. Flipping the Intake Manifold exposes the Throttle Body to allow its removal together with the accompanying seal. The installation process begins with tbod seal inspection and replacement when needed followed by tbod seal installation and position the Throttle Body at 10 nm (89 lb in). Begin by placing the Intake Manifold in its upright position to check the o-ring seals of evap purge solenoid and MAP Sensor before securing them with proper bolts that will be tightened to 10 nm (89 lb in). Place the Intake Manifold over its studs before securing bolts and nuts to 22 nm (16 lb ft). Secure the a/c line bracket bolt along with the high pressure Fuel Pump bracket bolt with a torque setting of 10 nm (89 lb in). Attach the Intake Manifold brace to its mounting points before installing the brace bolt loosely and tightening it to 25 nm (18 lb ft). After attaching the charge air bypass vacuum tank brace along with its nut and bolt the technician must tighten these components to 22 nm (16 lb ft). Next they will reconnect the wiring harness connector to the Intake Manifold brace. Use silicon-free engine oil gm p/n 12345610 (Canadian P/N 993193) or equivalent to lubricate the high pressure Fuel Pump fuel feed pipe connection threads before placing the fuel feed pipe on top of the Intake Manifold to connect it to the pump while tightening the bolts to 10 nm (89 lb in) and the fitting to 30 nm (22 lb ft). Secure the charge air bypass valve solenoid bolts using 10 nm (89 lb in) torque values while connecting the engine wiring harness electrical connector to the tac module as well as installing the knock sensor electrical connector clip onto the Intake Manifold brace. Install the brake booster hose followed by setting the brake booster vacuum hose clamp then join the MAP Sensor electrical connector. First install evap line quick connector fitting from evap purge solenoid then position the hose from evap hose clip and connect evap electrical connector to evap purge solenoid. The final steps include running the charge air bypass valve vacuum lines along with the charge air valve solenoid vacuum lines and electrical connector and fuel feed line quick connect fitting to the Fuel Rail before adding the oil level indicator tube and charge air cooler inlet pipe and air cleaner assembly and radiator air baffle and deflector.