GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Bonneville 🢒 Engine 🢒 Engine Electrical 🢒 Secondary Air Injection Shutoff Valve Replacement - Bank 1

Removal Procedure

    Object Number: 1212008 Size: SH
  1. Disconnect the electrical connector from the secondary air injection (AIR) shut-off valve.

    2. Object Number: 784720 Size: SH
  2. Remove the nut securing the intermediate hose/pipe to the AIR shut-off valve.
  3. Disconnect the intermediate hose from the AIR shut-off valve.

    4. Object Number: 1212009 Size: SH
  4. Remove the 2 nuts securing the outlet pipe to the exhaust manifold.
  5. Remove the 3 bolts securing the AIR shut-off valve to the cam cover.

    6. Remove the AIR shut-off valve, outlet pipe, and bracket from the engine.

    Discard the gasket.

  6. Remove the 2 nuts securing the outlet pipe and bracket to the AIR shut-off valve.

    7. Discard the gasket.

Installation Procedure

    Object Number: 1212009 Size: SH
  1. Position the secondary air injection (AIR) shut-off valve with a new outlet pipe gasket to the outlet pipe and bracket.

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

  2. Install the 2 nuts securing the outlet pipe and bracket to the AIR shut-off valve.

    3. Tighten
    Tighten the nuts to 9 N·m (80 lb in).

  3. Position a new outlet pipe gasket to the exhaust manifold.
  4. Position the AIR shut-off valve with the bracket to the cam cover and exhaust manifold.
  5. Install the 3 bolts securing the AIR shut-off valve to the cam cover.

    6. Tighten
    Tighten the bolts to 9 N·m (80 lb in).

  6. Install the 2 nuts securing the outlet pipe to the exhaust manifold.

    7. Tighten
    Tighten the nuts to 9 N·m (80 lb in).


    Object Number: 784720 Size: SH
  7. Connect the intermediate hose to the AIR shut-off valve.
  8. Install the nut securing the intermediate hose/pipe to the AIR shut-off valve.

    9. Tighten
    Tighten the nut to 9 N·m (80 lb in).


    Object Number: 1212008 Size: SH
  9. Connect the electrical connector to the AIR shut-off valve.