GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 OUTLOOK - FWD 🢒 Preface 🢒 Cautions and Notices 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 1861105 Size: SH
  1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Remove the intake manifold insulator. Refer to Intake Manifold Insulator Replacement .
  4. Disconnect the evaporative emissions (EVAP) canister purge line (1) and reposition aside.
  5. Disconnect the PCV line (2) from the top of the intake manifold and reposition aside.
  6. Disconnect the intake manifold tuning valve electrical connector (3).
  7. Remove the brake booster vacuum hose (4) from the intake manifold.
  8. Disconnect the electronic throttle control (ETC) electrical connector (5).

    9. Object Number: 1861153 Size: SH
  9. Remove the engine harness bracket retaining bolt (1).
  10. Disconnect the map sensor electrical connector (2).

    11. Object Number: 1861184 Size: SH
  11. Completely loosen but do not tighten the upper intake retaining bolts.
  12. Remove the upper intake manifold, gasket and bolts together. Discard gasket.
  13. If replacing the upper intake manifold complete the following steps:
    14. 13.1. Remove the evaporative emissions (EVAP) purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
    13.2. Remove the intake manifold tuning valve. Refer to Intake Manifold Tuning Valve Replacement .
    13.3. Remove the throttle body. Refer to Throttle Body Assembly Replacement .

Installation Procedure

    Object Number: 1861184 Size: SH
  1. Install the upper intake manifold gaskets to the lower intake manifold and install the fir tree retainers to retain the upper intake manifold gasket position.
  2. Install the bolts into the upper intake manifold.
  3. Apply threadlock to the bolt threads. Refer to Adhesives, Fluids, Lubricants, and Sealers .

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

  4. Install the upper intake manifold with bolts.

    5. Tighten
    Tighten the bolts to 23 N·m (17 lb ft).

  5. If the upper manifold was replaced, complete the following steps:
    6. 5.1. Install the throttle body. Refer to Throttle Body Assembly Replacement .
    5.2. Install the intake manifold tuning valve. Refer to Intake Manifold Tuning Valve Replacement .
    5.3. Install the EVAP purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .

    Object Number: 1861153 Size: SH
  6. Connect the map sensor electrical connector (2).
  7. Install the engine harness bracket retaining bolt (1).

    8. Object Number: 1861105 Size: SH
  8. Connect the ETC electrical connector (5).
  9. Install the brake booster vacuum hose (4) to the intake manifold.
  10. Connect the intake manifold tuning valve electrical connector (3).
  11. Connect the PCV line (2) to the top of the intake manifold.
  12. Connect the EVAP canister purge line (1).
  13. Install the intake manifold insulator. Refer to Intake Manifold Insulator Replacement .
  14. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  15. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .