OrngBalt

Anybody have the install instructions or done a how-to on 2.4 manifold on a 2.2?

YzRider452

I can walk you through it if you really need it.

scotch89

iTrader: (1)

look at where you type in how many u want it right above it saying download instructions heres the url but the instalation is way simple message me if u neeed help. (heres the url) http://www.crateenginedepot.com/stor...P1817C137.aspx

FacelessKhaos

Here you go:

Assuming you have all parts together: goto step 1

Parts Needed:

2.4 Manifold
Intake Seals x 4
Throttle Body Seal x 1
PCV Seal x 1
Flathead Screwdriver
10mm Socket
Extension (if needed)
Ratchet (preferably 3/8" with 1/4" reducer)
Rags
Brake Booster Line
05/06 Models, TB Adapter w/gasket, (07 Optional)

Step 1:

Unplug the battery and then Pop the hood, open it up. Take off the engine cover. Replace oil filler cap (don't want dust inside of it). Take off Air intake to get to the throttle body. Best advice is to take it entirely off so it won't get in the way.

Step 2:

Unplug the Throttle body electrics. Using your 10mm Socket/ratchet undo the 4 bolts holding the TB on. Put those aside. Once the TB is off, there is a blue/green rubber seal. Remove and set aside.

Step 3:

Undo the bolt holding the MAP Sensor (on top of the manifold). Unplug it and set it aside.

Step 4:

Undo all clips and wire guides from the manifold..there are a lot of them so be careful when removing. Move all the wires to the side, if you have to put a zip tie or some tape around them to hold them out of the way.

Step 5:

Using your 10mm Socket w/ extension, undo the manifold bolts in a crisscross pattern. Set them aside. Do not remove the Studs! Here comes the tricky part. Carefully remove the manifold, you may have to pull it out in an awkward position. On the head side of the manifold there are 4 blue/green rubber seals, remove them and set aside. The center seal CANNOT be reused for the install.

Step 6: (Omit if you have brand new seals)

Take the seals that you have removed from the 2.2 manifold and give them a once over with a rag. Inspect them for cracks and what not. Carefully install them into the 2.4 manifold if all is well.

Step 7:

Install the PCV Seal, on the 2.2 manifold it's just a rubber oval ring. On the 2.4 manifold it's a Copper Plate with a rubber trapezoidal seal around it. Install that in between #2 and #3 Cylinder outlets on the manifold.

Step 8:

CAREFULLY slide the new manifold into place using the studs as a guide. Bolt them down snug. DO NOT OVER TORQUE you will break off a bolt really fast if you do. Once they are tight, then they are good.

Step 9:

Get your throttle body adapter and gasket and line up with the throttle body using the bolts from the throttle body. Keep in mind that the gasket is between the plate and the TB, not between the manifold and plate. With everything aligned, put the TB and plate in the proper location. Bolt it down snuggly. Again do not over torque.

Step 10:

If you opted for a new brake booster line instead of the amended 2.2 line (which upon request i can tell you have to save 50 on that part and up to 150 on the entire kit) then right behind the brake master cylinder pull out that line, it will make an evil hiss noise at you. Connect the new line with a firm push, then connect to the manifold. The location of this new connection is beneath the TB instead of on the back side of the manifold.

Step 11:

Reconnect all wires and sensors. TB electrics, Map Sensor (for 07 see side note) also keep in mind that the MAP Sensor on the 2.4 has a slide bar and no bolt hole. Also keep in mind that there aren't as many wire positions on the 2.4 as there are on the 2.2 so use the new ones to your disclosure.

*NOTE: For 07 Cobalts you will need to enlarge the MAP Sensor hole before Installing. It's a bit smaller than 1/2" DO NOT OVERENLARGE!

Step 12:

Reinstall the air intake. Note that it will be slightly moved from original spot by about 2". If everything is connected, then connect the battery and start the car. If the car throws no codes or does not go into "limp mode" then all is well. However, if your car does throw a code then you will have to have that cleared either by a store/dealership or by somebody with a code scanner. If it keeps throwing a code after it has been cleared, then it's highly recommended that you put the 2.2 manifold back on.

Step 13:

If the car is running good, then you have the option of reinstalling the engine cover. However it will not mount up like it once did.


**NOTE: I am not responsible for any damages done to your vehicle. This is solely for information purposes. Any questions can be directed to me. Thanks!

Also, to get max performance, it's recommended to get a tune with a 2.4 Throttle Body as well, however that is optional. Note that the 2.4TB will not operate on the 2.2 without a tune!

Enjoy!!!

YzRider452

How Do U Connect The 2.4 Tb??????????

FacelessKhaos

Don't mistake me but i think you may need an adapter but then again it may just plug in with the stock harness. But either way you still need a tune. I personally haven't done it but several people on here have. Just gotta ask around about that. And you wont' need the TB Adapter if you do that.

OrngBalt

thanks guys!

YzRider452

I have the Throttle body. The harness doesnt just plug in. Anyone know aboutt an adapter or how the did it?

FacelessKhaos

I haven't a clue on the wiring for it...but if i may add a suggestion...this is something i did today.

With the install of the 2.4 manifold, i noticed the lag on the first part of the powerband. I have been running 93 or 89 octane depending on how i feel...so i decided to put new spark plugs in. I went with Bosch Platinum +2 and they make a difference. Lot harder pull i think and for 20 dollars. Good thing. Just something i did that worked better than expected.

OrngBalt

what year are you?

YzRider452

im and 07. And i cant run hotter plugs, Im running spray...

FacelessKhaos

I have an 07.

dragonkingg5

iTrader: (1)

im not running spray or have the 2.4 intake mani but should i run diff spark plugs right now? im trying out the 93 gas at the pumps. using stock plugs atm.

Spanky's Monkey

iTrader: (6)

platniums have been known to cause problems on some L61's. we run iradiums stock and i wouldn't suggest anything but, but that's just my opinion.

FacelessKhaos

So far i haven't had problems with the double platinum plugs. I will go back to iridium plugs when i got f/i. but for what i'm using the plugs for..they work good. and i wouldn't suggest going anything hotter unless you have a bit more air flow without f/i

teh_punk

you dont need 93 octane unless you're tuned for it. you will actually LOSE power by using higher octane than what your engine needs.

YzRider452

Hes right, unless ur sprayin, or tuned. Then 93 ONLY!

dragonkingg5

iTrader: (1)

i got the 07 tune that is tuned for 93 but i dont feel much diff from that either. guess i wont feel the real power til i get the 2.4 intake mani.
so i'll just wait for that

OrngBalt

07 tune? did you get tuned by a tuner or no? if you didnt, your car is not tuned for 93 from the dealership

teh_punk

yeah im confused about this "07 tune".. who did the tune?

MP81

iTrader: (2)

You got your engine tuned for 93...

That's genius.

"Hey, lets buy more expensive fuel for no reason!"

I always ran regular in my IROC...

OrngBalt

jeez... now guys are getting flamed for tuning....


we were just wondering where his tune was from.

dragonkingg5

iTrader: (1)

Tuned from Vince at trifecta darrrr

OrngBalt

oh, ok well that makes sense. you shoulda said a trifecta tune instead of an 07 tune.... that doesnt make any sense

scotch89

iTrader: (1)

i have a question what the hell is that green peace that plugs into the back of thee manifold and what is it for cause on my stock intake mani it didnt have that there was just a hole????