GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Engine 🢒 Engine Cooling 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 896381 Size: SH

    Notice: Never attempt to remove the intake manifold from a hot engine, allow the engine to cool to ambient temperature. The intake manifold is made of a composite plastic and can be damaged if it is removed when the engine is hot.

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner assembly.
  3. Disconnect the intake air temperature (IAT) sensor electrical connection.
  4. Disconnect the crankcase vent hose from the camshaft cover.
  5. Remove the air inlet hose.
  6. Disconnect the following electric connections:
    7. 6.1. Idle air control (IAC)
    6.2. Throttle position sensor (TPS)
    6.3. Manifold absolute pressure (MAP)

    Object Number: 896387 Size: SH
  7. Remove the engine harness from the top of the manifold and disconnect the harness from under the intake manifold.
  8. Remove the fuel pressure regulator vacuum pipe.
  9. Disconnect the EVAP purge solenoid hose from the throttle body.

    10. Important: Do not bend the throttle cable.

  10. Unclip the throttle cable and the brake booster pipe retaining clips.
  11. Remove the throttle cable from the throttle body linkage cam.
  12. Disconnect the brake booster vacuum pipe at the brake booster.

    13. Object Number: 895188 Size: SH
  13. Remove the oil level indicator tube.
  14. Remove the throttle body bolts and nuts. Secure the throttle cable bracket away from the engine.
  15. Remove the throttle body.

    16. Object Number: 895191 Size: SH
  16. Remove the intake manifold bolts and nuts.
  17. Remove the intake manifold and gasket assembly.

Installation Procedure

    Object Number: 895191 Size: SH

    Important: The intake manifold gasket assembly may be reused if the seal rings are not damaged.

  1. Install the intake manifold gasket assembly.
  2. Install the intake manifold onto the cylinder head.
  3. Install the intake manifold bolts and nuts.

    4. Tighten
    Tighten the intake manifold-to-cylinder head bolts to 10 N·m(89 lb in).


    Object Number: 895188 Size: SH

    Important: The throttle body seal ring may be reused if not damaged or cut.

  4. Install the throttle body seal ring into the seal ring groove.
  5. Install the throttle body onto the intake manifold.
  6. Install the throttle cable bracket onto the throttle body studs.
  7. Install the throttle body nuts and bolts.

    8. Tighten
    Tighten the throttle body bolts to 10 N·m(89 lb in).

  8. Install the oil level indicator tube and the tube fastener.

    9. Tighten
    Tighten the oil level indicator tube-to-intake manifold bolt to 10 N·m(89 lb in).


    Object Number: 896387 Size: SH
  9. Connect the brake booster vacuum pipe at the brake booster.

    10. Important: Do not bend the throttle cable.

  10. Install the throttle cable and the brake booster pipe into the retaining clips.
  11. Connect the throttle cable to the throttle body linkage cam.
  12. Connect the EVAP purge solenoid hose to the throttle body.

    13. Object Number: 895185 Size: SH
  13. Install and connect the fuel pressure regulator vacuum pipe to the throttle body and regulator.
  14. Route the engine wire harness on top of the engine and connect the additional harness clips under the intake manifold.
  15. Install the harness bracket bolts.

    16. Tighten
    Tighten the engine harness bracket bolts to 10 N·m(89 lb in).

  16. Connect these electrical connections:
    17. 16.1. Manifold absolute pressure (MAP)
    16.2. Throttle position sensor (TPS)
    16.3. Idle air control (IAC)

    Object Number: 896381 Size: SH
  17. Install the air inlet hose to the throttle body.
  18. Connect the crankcase vent hose to the camshaft cover.
  19. Connect the intake air temperature (IAT) electrical connection.
  20. Install the air cleaner assembly.
  21. Connect the negative battery cable.

    22. Tighten
    Tighten the battery terminal bolts to 17 N·m(13 lb ft).