GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 HHR 🢒 Engine 🢒 Engine Mechanical - 2.0L 🢒 Intake Manifold Installation

    Object Number: 1769718 Size: SH
  1. Install a NEW intake manifold gasket.
  2. Install the intake manifold.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the intake manifold bolts and nuts.

    4. Tighten

    1. Tighten the intake manifold bolts to 22 N·m (16 lb ft).
    2. Tighten the intake manifold nuts to 22 N·m (16 lb ft).

    Object Number: 1769715 Size: SH
  4. Install the intake manifold brace.
  5. Install the intake manifold brace bolt.

    6. Tighten
    Tighten the intake manifold brace bolt to 22 N·m (16 lb ft).

  6. Connect the rear knock sensor to the intake manifold brace.

    7. Object Number: 1769706 Size: SH
  7. Install the throttle body.
  8. Install the throttle body bolts.

    9. Tighten
    Tighten the throttle body bolts to 10 N·m (89 lb in).


    Object Number: 1769666 Size: SH
  9. Install the high pressure fuel pump noise insulator.
  10. Install the high pressure fuel pump cover.
  11. Install the high pressure fuel pump cover bolts.

    12. Tighten
    Tighten the fuel pump cover bolts to 10 N·m (89 lb in).


    Object Number: 1769663 Size: SH
  12. Lubricate the high pressure fuel pump fuel feed line connection threads with clean 5W30 engine oil.
  13. Install the fuel feed line.
  14. Install the fuel feed line bolts.
  15. Connect the low pressure fuel line nut.

    16. Tighten

    1. Tighten the low pressure fuel line nut to 30 N·m (22 lb ft).
    2. Tighten the fuel feed line bolts to 10 N·m (89 lb in).

    Object Number: 2045492 Size: SH
  16. If the engine is equipped with a charger AIR bypass tank assembly, complete the following procedure:
    17. 16.1. Install the charger AIR bypass valve tank assembly.
    16.2. Tighten the charger AIR bypass valve tank assembly bolt.

    Tighten
    Tighten the charger AIR bypass valve tank assembly bolt to 25 N·m (18 lb ft).

    16.3. Install the charger AIR bypass valve tank assembly nut.

    Tighten
    Tighten the charger AIR bypass valve tank assembly nut to 25 N·m (18 lb ft).

            Important: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location. The tube with retaining clamp located on the charger AIR bypass valve tank assembly left side connects to the charger AIR bypass valve solenoid. The right side permanently attached tube connects to the intake manifold.

    16.4. Connect the appropriate charger AIR bypass tube assembly to the intake manifold.

    Object Number: 2048166 Size: SH
  17. If the engine is equipped with a charger AIR bypass tank assembly, complete the following procedure:
    18. 17.1. Install the charger AIR bypass valve solenoid with charger AIR bypass tube assemblies.
    17.2. Install the charger AIR bypass valve solenoid bolts.

    Tighten
    Tighten the charger AIR bypass valve solenoid bolts to 10 N·m (89 lb in).

            Important: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location.

    17.3. Connect the charger AIR bypass tube assemblies and clamps from the charger AIR bypass valve solenoid to the turbocharger and vehicle.
    17.4. Connect the final charger AIR bypass tube assembly from the charger AIR bypass valve tank assembly to the charger AIR bypass valve solenoid.

    Object Number: 1769657 Size: SH
  18. If the engine is not equipped with a charger AIR bypass tank assembly, complete the following procedure:
    19. 18.1. Install the charger AIR bypass valve solenoid with charger AIR bypass tube assemblies.
    18.2. Install the charger AIR bypass valve solenoid bolts.

    Tighten
    Tighten the charger AIR bypass valve solenoid bolts to 10 N·m (89 lb in).

            Important: Ensure proper connection of the charger AIR bypass tube assemblies and retaining clips to maintain proper pressure. Connect each tube to the appropriate location.

    18.3. Connect the charger AIR bypass tube assemblies and clamps.