GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 L300/LW300 🢒 Engine 🢒 Engine Controls - 3.0L (L81) 🢒 Intake Plenum Replacement

Removal Procedure

    Object Number: 894285 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the air cleaner hose assembly from the throttle body.

    3. Object Number: 894680 Size: SH
  3. Disconnect the throttle body electrical connection.

    4. Object Number: 896429 Size: SH
  4. Remove the electrical connection and vacuum hoses from the intake plenum switch over the valve solenoid.
  5. Remove the vacuum hose from the fuel pressure regulator.

    6. Object Number: 896433 Size: SH
  6. Remove the front intake plenum hose clamps, pipe bolts, and plenum bolts.
  7. Lift the plenum and remove the throttle body heater hoses.
  8. Remove the intake plenum.

    9. Important: It is not necessary to remove the rear intake runner.

  9. Remove the front intake runner.

    10. Object Number: 894807 Size: SH
  10. Remove the throttle body nut and throttle body assembly.

Installation Procedure

    Object Number: 894807 Size: SH
  1. Install the throttle body gasket to the plenum.
  2. Install the throttle body to the plenum.

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

  3. Install the throttle body nuts.

    4. Tighten
    Tighten the throttle body nut to 8 N·m (71 lb in).


    Object Number: 896435 Size: SH
  4. Attach the heater and vent hose to the throttle body.
  5. Install the intake plenum and intake plenum bolts. Finger tighten the bolts.
  6. Install the EGR pipe bolts.

    7. Tighten
    Tighten the EGR pipe bolts to 25 N·m (18 lb ft).

  7. Install the intake plenum bolts.

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


    Object Number: 896433 Size: SH
  8. Install the front manifold runner and tighten the clamps.
  9. Install the intake runner bolts.

    10. Tighten
    Tighten the intake manifold runner bolts to 8 N·m (71 lb in).

  10. Connect the negative battery cable.

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