GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 ION 🢒 Vehicle Control Systems 🢒 Vehicle DTC Information 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1647528 Size: SH
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Disconnect the engine harness electrical connector (1) from the throttle actuator control (TAC).
  4. Disconnect the engine harness electrical connector (2) from the fuel injector harness.

    5. Object Number: 1647405 Size: SH
  5. Disconnect the engine harness clips (1, 3, 4) from the intake manifold.
  6. Disconnect the engine harness clip (2) from the oil level indicator tube.
  7. Disconnect the fuel injector electrical connector clip from the intake manifold.

    8. Object Number: 1647529 Size: SH
  8. Reposition the vacuum brake booster hose clamp (2) at the intake manifold.
  9. Remove the vacuum brake booster hose from the intake manifold.

    10. Object Number: 1628032 Size: SH
  10. Remove the throttle body bolts.

    11. Important: The throttle body seal is reusable, only replace the seal if damaged.

  11. Remove the throttle body and seal.
  12. Remove and inspect the throttle body seal.

    13. Object Number: 1623766 Size: SH
  13. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  15. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .

    16. Object Number: 1623769 Size: SH
  16. Remove the intake manifold lower bolts (1).

    17. Object Number: 1571773 Size: SH
  17. Remove the intake manifold upper bolt and nuts.
  18. Remove the intake manifold.

    19. Important: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.

  19. Remove and inspect the intake manifold gasket.

Installation Procedure

    Object Number: 1571773 Size: SH
  1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
  2. Install the intake manifold.
  3. Install the intake manifold upper bolt and nuts.

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


    Object Number: 1623769 Size: SH
  4. Install the intake manifold lower bolts (1).

    5. Tighten
    Tighten the bolts/nuts to 10 N·m (89 lb in).


    Object Number: 1623766 Size: SH
  5. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  6. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  7. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service .

    8. Object Number: 1628032 Size: SH
  8. Install a NEW throttle body seal if necessary, otherwise install the old seal.
  9. Position the throttle body.
  10. Install the throttle body bolts.

    11. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1647529 Size: SH
  11. Install the vacuum brake booster hose to the intake manifold.
  12. Position the vacuum brake booster hose clamp (2) at the intake manifold.

    13. Object Number: 1647405 Size: SH
  13. Connect the engine harness clips (1, 3, 4) to the intake manifold.
  14. Connect the engine harness clip (2) to the oil level indicator tube.
  15. Connect the fuel injector electrical connector clip to the intake manifold.

    16. Object Number: 1647528 Size: SH
  16. Connect the engine harness electrical connector (2) to the fuel injector harness.
  17. Connect the engine harness electrical connector (1) to the TAC.
  18. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  19. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .