How To: 2.4 Intake Manifold Swap on 2.2 - Chevy Cobalt Forum / Cobalt Reviews / Cobalt SS / Cobalt Parts
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post #1 of 29 (permalink) Old 08-07-2011, 09:46 AM Thread Starter
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How To: 2.4 Intake Manifold Swap on 2.2

Well I've had my 2.4 intake manifold on since april 2009, but this is a how to i did today because i cleaned my bay out and did basic tune up stuff so i figured i'd throw something together since its a common swap and i havent found any how-to's on it. so hope its good


TOOLS NEEDED:[LIST]
  • Flathead or 8mm
  • 10mm socket and ratchet
  • Laquer Thinner or Mineral Spirits(optional)
  • Couple of rags
  • Torque Wrench

It's this easy.




First: You will need to disconnect the Negative Terminal on the battery.
Then start by taking the hose clamps off from the intake as circled below
the one on the right, is underneath.

-you will need a flathead or 8mm socket.




then take the intake box off


Second: you will need to disconnect the Idle Air Control. (circled in red)
then,
you will need to take the throttle body bolts off 4x 10mm (circled in green)
after that,
you will need to disconnect the evap and the brake booster (also circled in red)

(disregard the random dots haha)




Third: You will need to take the manifold bolts out of the cylinder head. (10mm socket and ratchet)

circled here in red


This is what it'll look like once you get that out of the way.



At this point in time, i recommend that VERY CAREFULLY, taking a little bit of laquer thinner or mineral spirits and clean the cylinder head surface and the surface of the manifold of any debris because you dont want anything creating a vaccum leak on the surface.

If bought used from another member, junkyard, or however you acquire it, take the gaskets out of clean them really well, like i said be careful not to get debris in the manifold itself. If bought new from CrateEngineDepot or some other source you probably will not have to clean the gaskets and what not.




Fourth: while you got everything off you mise well clean your throttle body out from all the carbon and crap built up.

Now on my TB you'll see a metal plate, from what ive been reading, theres apparently an air leak thats created if you use the 2.2 tb w/ the 2.4 manifold so you'll need the spacer that CrateEngineDepot provides.

heres the link :
Ecotec 2.2MMGF Spacer Plate Kit 2.2Plate - Crate Engine Depot



I ran it without the plate for a couple months, so youlll be ok if you dont have it right away.



Fifth: Once you got everythiing cleaned it's time to go back together!

-Make sure all gaskets are cleaned and seated correctly.
-connect EVAP
-connect Brake Booster
-connect IAT sensor
-and connect any other like things that were attached to the manifold.

Sixth: Put the throttle body back on, if you dont know the torque specs dont crank the bolts to tight, just enough to tighten and wont rattle loose and you seal the gaskets.

Toque specs for TB and IM: 89 in/lbs

Once you got your TB back on, connect your IAC (Idle Air Control)

Last: Put Your airbox back on, and make sure to connect your Negative Terminal on your battery back up! Once you start your car back up, let it sit there and idle for a minute or two and let everything compensate. Then Enjoy!


Anything i left out or opinions let me know!

<img src=http://i51.tinypic.com/154yqon.jpg border=0 alt= />

Last edited by bluecobaltls; 08-11-2011 at 07:14 AM.
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post #2 of 29 (permalink) Old 08-07-2011, 11:19 AM
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Great write up, thanks
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post #3 of 29 (permalink) Old 08-07-2011, 11:30 AM
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great write up looks easy enough, how were the gains? is it worth it in your opinion?
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post #4 of 29 (permalink) Old 08-07-2011, 11:41 AM
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it's worth it if you get a good price on it (150 or less), but it's not night and day difference.

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post #5 of 29 (permalink) Old 08-07-2011, 12:09 PM
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gotcha is it worth it to also get the 2.4 tb? i know a tune could never hurt anyways
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post #6 of 29 (permalink) Old 08-07-2011, 01:15 PM
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Cant run the 2.4 tb without a tune
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post #7 of 29 (permalink) Old 08-07-2011, 02:06 PM
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yes definitely worth getting a tune and the throttle body. look around on ebay and the forums. i got my 2.4 intake mani and throttle body, both brand new and shipped for 80 bucks

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post #8 of 29 (permalink) Old 08-07-2011, 05:53 PM Thread Starter
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well i did this swap like last year sometime, but like the beginning says i was doing some tune up stuff. but like 5-6500 rpms is where you really notice it. 2.4 tb is nice, but like everyone says you need a tune. but apprently with full bolt ons and tune, the car runs completely different.

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post #9 of 29 (permalink) Old 08-07-2011, 06:59 PM
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It runs completely different because the a/f and timing get changed with the tune. Everything is being used to its fullest potential instead of getting used half assed without a tune

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post #10 of 29 (permalink) Old 08-07-2011, 08:23 PM
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I wAs going to say it should run different after A tune. My main concern is that my balt is my daily I'll it be just as dependable as it is now and thAt I wouldn't be damaging my Balt in anywAy after the tune
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