Those who have been on the forum long enough know about the alteration which needs to be made to the CGS cold air intakes in order for them to fit over the coil/module assemblies on the 2.2's in the 2006 HHR's, an alteration which is no longer necessary in the 2007's.

Those who know me on this forum knows that my wife is an engineer at the plant which builds the 2.2, and as such she is intimately familiar with the engine at the point of assembly.

Much to my surprise, it was a news revelation that the coil/module assembly in 2006 even existed. From what she has told me, the four-coil setup is what Tonawanda has put on that engine for the entire time she has been there (she started in June of '04), and was on all of the engines shipped to Ramos Arizpe for the HHR, because it has to be installed at Tonawanda before the engines even leave the line. According to her, there's no logical reason why the '06 HHR's should have the coil/module assemblies, except for two possibilities:

1) the original run of '06 HHR's had Spring Hill engines, and the Tonawanda engines were put in as a running change; or

2) (more likely) the four-coil setup was removed at Ramos and replaced with the coil/module assemblies.

I would love to hear any opinions on this, in particular Snoopy's take.

 

I have no f...ing idea

My GUESS, if that's the case, is the engines came from Saturn. If the engines came from "The Ton", I would think sending the engines COMPLETE to the assembly plant, then removing the old and installing the new coils/modules would be labor intensive....even for cheap labor. I mean cripes, were talking 20,000-30,000 engines here. It would just cause to many headaches.

Again just a guess

 

I think Ton only produced the LE5 in 2006. Spring Hill made the L61 and LSJ. The L61 and LSJ always had the coil cassette setup since introduction through mid-year '07 when the Gen-II engine was introduced. In order to do an assembly plant swap of the ignition system, they'd have to replace the valve cover on the engine. That goes beyond the basic engine dress capabilities of most GM assembly plants.

 

Actually I have NO IDEA what modification need to be made Re: Intakes, can you point me in the right direction?

 

Here ya go bisho1p...a quick how to on what I did to mine for the 2.2

https://www.chevyhhr.net/forums/how-tutorial-library-21/modifying-cgs-2-2l-5375/

 

I'd try to come up with a different solution. You're tightening a metal part down onto a plastic cassette that holds the coil pack and ignition buss. Bad idea, especially given some of the *ahem* issues certain 2.2 CGS-equipped owners have been experiencing lately with bad coil packs and cracked cassettes.