GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 SKY 🢒 Diagnostic Navigation 🢒 Vehicle Diagnostic Information 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1571757 Size: SH
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  2. Remove the throttle body. Refer to Throttle Body Assembly Replacement.
  3. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.
  4. Remove the evaporative emission (EVAP) canister purge solenoid valve tube. Refer to Plastic Collar Quick Connect Fitting Service.

    5. Object Number: 1590611 Size: SH
  5. Reposition the brake booster vacuum hose clamp at the intake manifold.
  6. Remove the brake booster hose from the intake manifold.
  7. Remove the oil level indicator tube bolt.

    8. Object Number: 1590626 Size: SH
  8. Disconnect the engine harness electrical connector (1) from the fuel injector electrical connector.
  9. Disconnect the electronic throttle actuator electrical connector (3).

    10. Object Number: 1590536 Size: SH
  10. Disconnect the windshield wiper motor electrical connector.
  11. Remove the engine harness clip from the wiper motor.

    12. Object Number: 1590557 Size: SH
  12. Remove the engine harness clip from the surge tank air bleed hose.

    13. Object Number: 1590504 Size: SH
  13. Reposition the radiator surge tank air bleed hose clamp at the engine (1).
  14. Remove the air bleed hose (2) from the engine and reposition.

    15. Object Number: 1590533 Size: SH
  15. Disconnect the air conditioning (A/C) refrigerant pressure sensor electrical connector.

    16. Object Number: 1590535 Size: SH
  16. Remove the engine harness clip (4) from the intake manifold.

    17. Object Number: 1590505 Size: SH
  17. Disconnect the engine harness electrical connector (3) from the knock sensor harness.
  18. Remove the knock sensor connector clip from the oil level indicator tube.
  19. Reposition the engine harness.

    20. Object Number: 1571773 Size: SH
  20. Remove the intake manifold bolts and nuts.
  21. Remove the intake manifold.

    22. Note: The intake manifold gasket is reusable. Only replace the gasket if damage has occurred.

  22. Remove the intake manifold gasket, if necessary.

Installation Procedure

    Object Number: 1571773 Size: SH
  1. Install the intake manifold gasket, if necessary.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the intake manifold.
  3. Install the intake manifold bolts and nuts.

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


    Object Number: 1590505 Size: SH
  4. Position the engine harness.
  5. Install the knock sensor connector clip to the oil level indicator tube.
  6. Connect the engine harness electrical connector (3) to the knock sensor harness.

    7. Object Number: 1590535 Size: SH
  7. Install the engine harness clip (4) to the intake manifold.

    8. Object Number: 1590533 Size: SH
  8. Connect the A/C refrigerant pressure sensor electrical connector.

    9. Object Number: 1590504 Size: SH
  9. Position and install the air bleed hose (2) to the engine.
  10. Position the radiator surge tank air bleed hose clamp at the engine (1).

    11. Object Number: 1590557 Size: SH
  11. Install the engine harness clip to the surge tank air bleed hose.

    12. Object Number: 1590536 Size: SH
  12. Connect the windshield wiper motor electrical connector.
  13. Install the engine harness clip to the wiper motor.

    14. Object Number: 1590626 Size: SH
  14. Connect the electronic throttle actuator electrical connector (3).
  15. Connect the engine harness electrical connector (1) to the fuel injector electrical connector.
  16. Install the oil level indicator tube bolt.

    17. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1590611 Size: SH
  17. Install the brake booster hose to the intake manifold.
  18. Position the brake booster vacuum hose clamp at the intake manifold.

    19. Object Number: 1571757 Size: SH
  19. Install the EVAP canister purge solenoid valve tube. Refer to Plastic Collar Quick Connect Fitting Service.
  20. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.
  21. Install the throttle body. Refer to Throttle Body Assembly Replacement.
  22. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.