INTAKE MANIFOLD

REMOVAL

1. Disconnect negative battery terminal.
2. Drain engine coolant. Refer to "Engine Coolant Check and Replacement" in the Cooling System.
3. Remove air inlet tube and air filter cover, disconnecting fresh air hose at cam cover.
4. Remove PCV valve hose.

1. Relieve fuel system pressure. Refer to "Relieving Fuel Pressure" in the Fuel System.

1. Remove screw from fuel line clip and disconnect fuel line from rail.

1. Disconnect throttle cable from throttle body.
2. Remove throttle cable bracket attaching nuts.

1. Remove the following electrical connectors and harness wiring:

• • Fuel Injectors
  • Throttle position (TP) sensor
  • Idle air control (IAC)
  • Manifold absolute pressure (MAP) sensor
  • EGR valve

1. Disconnect heater and hose at intake manifold outlet.

1. Lay harness over brake master cylinder.
2. Remove the intake manifold support bracket bolt attached to the intake manifold located below the throttle body. IMPORTANT: Label vacuum lines to make sure they are replaced properly.

1. Remove accessory drive belt.
2. Remove power steering pump assembly. Remove power steering pump bracket attachment bolts and position pump next to the right-hand front of dash panel, away from the cylinder head and intake manifold.
3. Remove the four upper intake manifold attachment nuts.

1. Raise vehicle.

1. Disconnect vacuum hose at the EVAP canister purge solenoid and brake booster.

1. Remove 5 lower intake manifold attaching nuts.
2. Lower vehicle to floor.
3. Remove intake manifold assembly.
4. Remove intake manifold gasket and discard. Clean cylinder head and intake manifold gasket sealing surfaces. Inspect surfaces as outlines in the "SOHC (L24) Cylinder Head". IMPORTANT: Clean and inspect cylinder head and intake manifold aluminum surfaces as outlined on the SOHC (L24: engine cylinder head.

INSTALLATION

IMPORTANT: Make sure cylinder head and air intake manifold gasket sealing surfaces is clean. Refer to "SOHC (L24) Cylinder Head" section for inspection requirements. Use Saturn P/N 21485276 Loctite 290(R) (or equivalent) to seal a PCV valve inlet tube into the manifold if replaced.

1. Install new intake manifold gasket.
2. Install intake manifold onto attaching studs.
3. Install intake manifold attaching nuts.
4. In sequence, torque the intake manifold attaching nuts. Torque: Intake Manifold-to-Head (L24): 30 N.m (22 ft-lbs)

1. Install power steering pump assembly. Refer to Power Steering Pump" installation procedure in the steering section of the Chassis. Torque: Power Steering Pump-to-Bracket: 30 N.m (22 ft-lbs)
2. Install accessory drive belt. Make sure belt is properly aligned on the pulleys.
3. Connect the heater hose at intake manifold outlets. Make sure it is firmly seated.

NOTE: Replace plastic fuel retainer whenever the fuel supply is disconnect at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

1. Connect fuel supply line and fasten fuel line clip to brace. Torque: Fuel Line Retainer Clip: 4 N.m (35 in-lbs) IMPORTANT: When the throttle cable is removed, make sure the locking tangs are fully engaged when assembled if disconnected.

1. Connect throttle cable to throttle body, and throttle cable support bracket. Attach the accelerator control cable bracket. Torque: Accelerator Control Cable Bracket-to-Intake Manifold (L24): 30 N.m (22 ft-lbs) IMPORTANT: Make sure to confirm positive engagement of electrical connectors and vacuum hoses.
2. Install the following electrical harness connectors and vacuum hoses.

• Idle air control (IAC)
• Throttle position (TP) Sensor
• Manifold absolute pressure (MAP) Sensor
• Fuel injectors (4)
• EGR

• EVAP canister purge solenoid

1. Install PCV hose.
2. Install air inlet tube, fresh air hose, and air filter cover.
3. Connect negative battery terminal. Torque: Battery Terminal Bolts: 17 N.m (13 ft-lbs)
4. With engine off and ignition on, pressurize the fuel system and check for fuel leaks.
5. Install cylinder block drain plugs and close radiator drain. Torque: Cylinder Block Drain Plugs: 35 N.m (26 ft-lbs)
6. Fill with coolant. Use only a non-phosphate ethylene glycol-based antifreeze. IMPORTANT: Vehicle must be level when filling coolant.
7. Prime fuel system.

1. Start engine and check for leaks.
2. Fill the cooling system surge bottle to the cold full line. Check coolant level after the engine has run for two to three minutes .