GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 L300/LW300 🢒 Engine 🢒 Engine Electrical 🢒 Intake Manifold Replacement

Tools Required

    • J 43914 Universal Clamp Pliers
    • SA9805E Fuel Line Separator

Removal Procedure

    Object Number: 896437 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the intake plenum. Intake Plenum Replacement .

    3. Object Number: 896453 Size: SH
  3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.0L (L81).
  4. Remove the fuel supply hose from the fuel rail using the SA9805E .
  5. Remove the fuel return hose from the fuel rail using the SA9805E .
  6. Disconnect the fuel injector electrical harness connector.
  7. Remove the fuel injector connectors.
  8. Remove the fuel injector harness.
  9. Remove the fuel rail bolts.
  10. Remove the fuel rail.

    11. Object Number: 896462 Size: SH
  11. Remove the intake manifold bolts.
  12. Remove the intake manifold.

    13. Notice: Use extreme care and do not damage or scratch the machined aluminum surfaces. Leaks will result.

  13. Remove the manifold spacer bolts.
  14. Remove the manifold spacer.
  15. Remove the sealing rings.
  16. Clean the manifold sealing surfaces with a nonabrasive tool or solvent.

Installation Procedure

    Object Number: 896462 Size: SH
  1. Remove the masking from the intake ports.
  2. Install the manifold gaskets.
  3. Install the manifold spacer.
  4. Install the manifold spacer bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

    5. Tighten
    Tighten the intake manifold spacer bolt to 20 N·m (15 lb ft).

  5. Install the intake manifold gaskets.
  6. Install the intake manifold.
  7. Install the intake manifold bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

    8. Tighten
    Tighten the intake manifold bolt to 20 N·m (15 lb ft).


    Object Number: 896453 Size: SH
  8. Install the fuel injector electrical harness and connectors.
  9. Install the fuel rail.

    10. Tighten
    Tighten the fuel rail bolts to 8 N·m (71 lb in).


    Object Number: 896435 Size: SH
  10. Connect the fuel supply hose.
  11. Connect the fuel return hose.
  12. Install the upper intake plenum.
  13. Install the plenum bolts and EGR manifold bolt.

    14. Tighten

        • Tighten the intake plenum bolts to 8 N·m (71 lb in).
        • Tighten the EGR manifold bolt to 8 N·m (71 lb in).
  14. Install the intake plenum clamp using the J 43914 .
  15. Connect the negative battery cable.

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

  16. Crank the engine but do not start. Check for fuel leaks.