GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Engine 🢒 Engine Mechanical - 2.2L (L61) 🢒 Intake Manifold Installation

    Object Number: 412542 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the intake manifold studs in the manifold face.

    2. Tighten
    Tighten the intake manifold studs to 5 N·m (44 lb in).


    Object Number: 746066 Size: SH
  2. Install a new intake manifold gasket on the intake manifold.
  3. Install the intake manifold.
  4. Install the intake manifold bolts and nuts. Follow the tightening sequence.

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


    Object Number: 746065 Size: SH
  5. Install the fuel rail assembly.
  6. Install the fuel rail stud.

    7. Tighten
    Tighten the stud to 10 N·m (89 lb in).


    Object Number: 746082 Size: SH
  7. Install new throttle body stud if necessary.

    8. Tighten
    Tighten the studs to 6 N·m (60 lb in).


    Object Number: 750019 Size: SH
  8. Install a new throttle body gasket.
  9. Install the throttle body.

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


    Object Number: 825004 Size: SH

    Important: Ensure that the rear metal tab of the EVAP emission canister valve is resting on the power steering pump metal body.

  10. Install the EVAP emission canister valve (2).

    11. Tighten
    Tighten the EVAP canister valve to 22 N·m (16 lb ft).

  11. Install the EVAP emission canister valve tube (1).

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 895087 Size: SH
  1. Install the intake manifold studs in the cylinder head.

    2. Tighten
    Tighten the intake manifold-to-cylinder head studs to 6 N·m (60 lb in).


    Object Number: 895191 Size: SH
  2. Install a new intake manifold gasket onto the intake manifold.
  3. Install the intake manifold.
  4. Install the intake manifold bolts and nuts. Tighten by starting from the center bolt and working outward.

    5. Tighten

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

    Object Number: 895190 Size: SH
  5. Install the fuel rail assembly.
  6. Install the fuel rail stud.

    7. Tighten
    Tighten the fuel rail bracket stud to 10 N·m (89 lb in).


    Object Number: 895188 Size: SH
  7. Install the throttle body. The gasket may be reused if not damaged.

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


    Object Number: 895185 Size: SH
  8. Install the pressure regulator vacuum harness.

    9. Object Number: 897471 Size: SH
  9. Install the knock sensor connector onto the intake manifold.