GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 Astra 🢒 Engine 🢒 Engine Mechanical - 1.8L (2H0) 🢒 Intake Manifold Installation

Special Tools

KM-807 Closure Plugs


    Object Number: 1945783 Size: SH
  1. Clean the sealing surfaces.
  2. Insert 4 NEW gaskets.

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

  3. Install the intake manifold and bolts (1).

    4. Tighten
    Tighten the 7 bolts to 20 N·m (15 lb ft).


    Object Number: 1945782 Size: SH
  4. Insert a NEW gasket.
  5. Install the throttle valve module and bolts (1).

    6. Tighten
    Tighten the 4 bolts to 9 N·m (80 lb in).


    Object Number: 1944890 Size: SH
  6. Install the brake servo vacuum line (1) to the intake manifold.
  7. Connect the quick release fitting.

    8. Object Number: 1945781 Size: SH
  8. Install the wiring harness bracket (1) to the engine transport shackle.
  9. Install the bolt (2).

    10. Tighten
    Tighten the bolt.


    Object Number: 1945780 Size: SH
  10. Connect the 2 wiring harness plugs.
    11. • Vacuum unit change-over valves (1)
    • Solenoid valve for change-over valves (2)

    Object Number: 1945778 Size: SH
  11. Install the return line, fuel/air mixture preheating (1).
    12. 11.1. Connect the throttle valve module.
    11.2. Fasten the clamp.
    11.3. Connect the coolant expansion tank.
    11.4. Fasten the clamp.
    11.5. Install the intake manifold.
    11.6. Install the 3 brackets.
  12. Install the supply line, fuel/air mixture preheating (2).
    13. 12.1. Connect to the thermostat housing.
    12.2. Connect the quick release fitting.
    12.3. Install the throttle valve module.
    12.4. Fasten the clamp.
    12.5. Install the intake manifold.
    12.6. Connect the 4 brackets.

    Object Number: 1944870 Size: SH
  13. Connect the wiring harness plug (1).

    14. Object Number: 1945777 Size: SH
  14. Install the engine management wiring harness.
    15. 14.1. Connect the 7 wiring harness plugs:
       • Air mass flow meter
       • Throttle valve module
       • Valve, intake camshaft adjustment
       • 4 injector valves
    14.2. Clip on the 2 wiring harness brackets.
  15. Install the engine control module (ECM). Refer to Engine Control Module Replacement.
  16. Install the engine vent hose (1).
    17. • Connect the 2 quick-release fittings.
    • Clip the wiring harness to the cylinder head.

    Object Number: 1940561 Size: SH
  17. Apply silicone grease, white, to the injector seal rings and install onto the injection valves.

    18. Important: Inspect the installation position to ensure correct fitting.

  18. Install the injector valves to the fuel rail and attach with the retaining clamps (1).

    19. Object Number: 1945797 Size: SH
  19. Install the fuel rail (2) and 2 bolts (1).

    20. Tighten
    Tighten the bolts to 8 N·m (71 lb in).


    Object Number: 1944873 Size: SH
  20. Install the fuel supply line (1) to the fuel rail.
    21. • Remove the 2  KM-807 .
    • Connect the quick release fitting.
    • Clip into the bracket.

    Object Number: 1945777 Size: SH
  21. Attach the engine management wiring harness.
    22. 21.1. Connect the following 9 wiring harness plugs:
           - Engine control unit
           - Air mass flow meter
           - Tank vent valve
           - Throttle valve module
           - Intake camshaft actuator
           - 4 injector valves
    21.2. Clip on the 2 wiring harness brackets.
  22. Install the engine vent hose (1).
    23. 22.1. Connect the 2 quick-release fittings.
    22.2. Clip the wiring harness to the cylinder head.

    Object Number: 1944873 Size: SH
  23. Install the fuel supply line (1) to the fuel rail.
    24. 23.1. Remove KM-807 .
    23.2. Connect the quick-release fitting.
    23.3. Install into the bracket.

    Object Number: 1945776 Size: SH
  24. Connect the tank vent valve to the intake manifold.
    25. • Connect the line (1) to the intake manifold.
    • Connect the rubber mounting (3) to the bracket.
    • Install the wiring harness plug (2).

    Object Number: 1945774 Size: SH
  25. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
  26. Install the wiring harness to the intake manifold.
  27. Install the intake manifold support (2) and the bolts (3).

    28. Tighten
    Tighten the 2 bolts to 8 N·m (71 lb in).

    • Connect the wiring harness plug (1) into the bracket.
    • Connect the catalytic converter control oxygen sensor wiring harness plug.