Intake Manifold Replacement SOHC L24

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

1. Disconnect the negative battery terminal.
2. Drain the engine coolant.
3. Remove the air inlet tube and the air filter cover, disconnecting the fresh air hose at the cam cover.
4. Remove the PCV valve hose.

Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.

5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls.



6. Remove the screw from the fuel line clip and disconnect the fuel line from the rail.



7. Disconnect the throttle cable from the throttle body.
8. Remove the throttle cable bracket attaching nuts.



9. Remove the following electrical connectors and harness wiring:

•	The fuel Injectors

•	The throttle position (TP) sensor

•	The idle air control (IAC)

•	The manifold absolute pressure (MAP) sensor

•	The exhaust gas recirculation (EGR) valve

10. Disconnect the heater and hose at the intake manifold outlet.



11. Lay the harness over the brake master cylinder.
12. Remove the intake manifold support bracket bolt attached to the intake manifold located below the throttle body.




Important:  Label vacuum lines to make sure they are replaced properly.

13. Remove the accessory drive belt.
14. Remove the power steering pump assembly. Remove the power steering pump bracket attachment bolts and position the pump next to the right-hand front of dash panel, away from the cylinder head and intake manifold.
15. Remove the 4 upper intake manifold attachment nuts.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

16. Raise the vehicle.



17. Disconnect the vacuum hose at the evaporate emissions (EVAP) canister purge solenoid and brake booster.



18. Remove the 5 lower intake manifold attaching nuts.
19. Lower the vehicle to floor.
20. Remove the intake manifold assembly.

Important: Clean and inspect cylinder head and intake manifold aluminum surfaces as outlined on the SOHC (L24) engine cylinder head section in this service manual.

21. Remove the intake manifold gasket and discard. Clean the cylinder head and the intake manifold gasket sealing surfaces. Inspect the surfaces as outlines in the "SOHC (L24) Cylinder Head" section in this service manual.

Important: Ensure that the cylinder head and air intake manifold gasket sealing surfaces is clean. Refer to "SOHC (L24) Cylinder Head" section for inspection requirements. Use Saturn P/N 21485276 Loctite 290® (or equivalent) to seal a PCV valve inlet tube into the manifold if replaced.

1. Install the new intake manifold gasket.
2. Install the intake manifold onto attaching studs.
3. Install the intake manifold attaching nuts.
4. In sequence, torque the intake manifold attaching nuts.

Tighten
Tighten the intake manifold-to-head (L24) upper side in a 8-4-1-5 sequence and the lower side in a 7-3-2-6-9 sequence to 30 N·m (22 lb ft).

5. Install the power steering pump assembly. Refer to Power Steering Pump Replacement installation procedure in Power Steering System.

Tighten
Tighten the power steering pump-to-bracket to 30 N·m (22 lb ft).

6. Install the accessory drive belt. Ensure that the belt is properly aligned on the pulleys.
7. Connect the heater hose at the intake manifold outlets. Ensure that it is firmly seated.




Caution: Whenever fuel line connectors are disconnected, lubricate steel line male ends with clean engine oil. Holding the steel line, firmly press on the female coupler until a click is heard, then pull back to confirm engagement. Make sure the fuel line connects are fully seated. Pinched, kinked, or damaged fuel lines must be replaced.

Notice: Replace plastic fuel retainer whenever the fuel supply is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

8. Connect the fuel supply line and fasten the fuel line clip to the brace.

Tighten
Tighten the fuel line retainer clip 4 N·m (35 lb in).





Important: When the throttle cable is removed, ensure that the locking tangs are fully engaged when assembled, if disconnected.

9. Connect the throttle cable to the throttle body, and the throttle cable support bracket. Attach the accelerator control cable bracket.

Tighten
Tighten the accelerator control cable bracket-to-intake manifold  (L24) 30 N·m (22 lb ft).

Important:  Make sure to confirm positive engagement of electrical connectors and vacuum hoses.

10. Install the following electrical harness connectors and vacuum hoses.

10.1.

Electrical connectors:

•	The idle air control (IAC)

•	The throttle position (TP) Sensor

•	The manifold absolute pressure (MAP) Sensor

•	The fuel injectors (4)

•

The EGR

10.2.

Vacuum Hoses:

The EVAP canister purge solenoid




11. Install the PCV hose.
12. Install the air inlet tube, fresh air hose, and air filter cover.
13. Connect the negative battery terminal.

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

14. With the engine OFF and ignition ON, pressurize the fuel system and check for fuel leaks.
15. Install the cylinder block drain plugs and close the radiator drain.

Tighten
Tighten the cylinder block drain plugs to 35 N·m (26 lb ft).

16. Fill the cooling system with coolant. Use only a non-phosphate ethylene glycol-based antifreeze.

Important: The vehicle must be level when filling coolant.

17. Prime the fuel system.

17.1.

Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.

17.2.

Repeat step 17.1 twice.

17.3.

Crank the engine until it starts. Maximum starter motor cranking time is 20 seconds.

17.4.

If the engine does not start, repeat steps 17.1 -17.3.

18. Start the engine and check for leaks.
19. Fill the cooling system surge bottle to the cold full line. Check the coolant level after the engine has run for 2-3 minutes.

Intake Manifold Replacement DOHC LL0

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

1. Raise the vehicle.



2. Drain the engine coolant. Drains are located at the right front corner of the engine block and right-hand side of the radiator.



3. Place a 1 in x 1 in x 2 in long block of wood between the torque strut and cradle.




Important: Installation of the wood block prior to upper engine torque axis mount removal allows the mount to be easily removed without lifting or jacking the powertrain.

4. Remove the fastener at the bottom of the intake manifold that attaches the intake manifold brace to the intake manifold.
5. Lower the vehicle.



6. Disconnect the negative battery terminal



7. Remove the air inlet tube and the air filter cover, disconnecting the fresh air hose at the air inlet duct.
8. Remove the PCV valve hose at the cam cover.

Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.

9. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls.



10. Remove the nut at the fuel line clip and disconnect the fuel line from the rail.



11. Disconnect the throttle cable from the throttle body.
12. Remove the throttle cable from the cable bracket.
13. Disconnect the vacuum harness from the throttle body.



14. Remove the following electrical connectors and harness wiring:

•	The fuel injectors

•	The throttle position (TP) sensor

•	The idle air control valve (IAC)

•	The manifold absolute pressure (MAP) sensor

•	The exhaust gas recirculation (EGR) valve

15. Move the harness to the front of the dash.



16. Disconnect the heater and deaeration hoses at the intake manifold outlets.
17. Remove the power steering support brace.



18. Remove the fuel rail.



19. Disconnect the EGR pipe from the cylinder head.
20. Disconnect the vacuum hose at the brake booster.
21. Remove the accessory drive belt.



22. Remove the power steering pump assembly with the support bracket.
23. Remove the upper power steering pump bracket attachment bolts and position the pump next to the right-hand front of the dash panel, away from the cylinder head and intake manifold. Refer to Power Steering Pump Replacement in Power Steering System.



24. Remove the 3 right-hand, upper engine torque axis mount to front cover nuts and the 2 mount to midrail bracket nuts, allowing the powertrain to rest on the block of wood, and remove the mount



25. Remove the resonator and air cleaner box.
26. Disconnect the air temperature sensor.



27. Remove the transaxle strut-to-midrail bolt.



28. Rotate the top of engine forward and secure the engine with tie straps or mechanic's wire. The tie straps can be routed from the front engine lift hook to the radiator support.



29. Remove the intake manifold fasteners and remove the intake manifold.

Important: Ensure that the cylinder head and intake manifold gasket sealing surfaces are clean. Refer to DOHC (LL0) Cylinder Head section for inspection requirements. Inspect intake manifold gasket for cuts, nicks, or swelling. Replace if any of these conditions are found.

1. Assemble the EGR pipe assembly to the intake manifold.

Tighten
Tighten the EGR pipe-to-intake manifold (LL0) 10 N·m (89 lb in).

2. Install the intake manifold onto the attaching studs.
3. Install the intake manifold attaching nuts.



4. In sequence, torque the intake manifold attaching nuts.

Tighten
Tighten the intake manifold-to-head (LL0) to 13 N·m (9.5 lb ft).

5. Install the EGR pipe with a new gasket to the cylinder head.

Tighten
Tighten the EGR pipe-to-cylinder head (LL0) to 25 N·m (19 lb ft).




6. Connect the heater and deaeration hoses to the intake manifold outlets.

Important: Lubricate the O-rings at the injector tips prior to installing the injectors into the intake manifold.

7. Install the fuel rail.

Tighten
Tighten the fuel rail attachment bolts to 12 N·m (9 lb ft).




8. Install the following electrical harness connectors and vacuum hoses.

8.1.	Electrical connectors:

•	The idle air control valve (IAC)

•	The throttle position (TP) sensor

•	The manifold absolute pressure (MAP) sensor

•	The fuel injectors (4)

•	The EGR valve

8.2.	Vacuum hoses:

The EVAP canister purge solenoid




9. Install the vacuum line to the brake booster.
10. Install the PCV valve and hose to the cam cover.



11. Assemble the fuel line nut to the fuel line stud at the intake manifold.

Tighten
Tighten the fuel feed line support clip-to-bracket (LL0) to 4.5 N·m (37 lb in).

Notice: Replace plastic fuel retainer whenever the fuel supply is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

12. Attach the line to fuel rail.



13. Install the power steering pump assembly and brackets.

Tighten
Tighten the power steering pump bracket-to-block to 30 N·m (22 lb ft).

14. Install the power steering pump brace.

Tighten
Tighten the power steering pump brace-to-block to 30 N·m (22 lb ft).




15. Install the accessory drive belt.
16. Install the transaxle mount to frame rail.

Tighten
Tighten the transaxle mount-to-frame rail to 70 N·m (52 lb ft).





Notice: To prevent engine front cover and mount damage, the three front engine mount-to-front cover nuts must be tightened down uniformly.

17. Install the engine mount-to-midrail bracket nuts first.
18. Next, install the 3 engine mount-to-front cover nuts.
19. Remove the block of wood from under the torque strut after the engine mount assembly is installed.

Tighten

•	Tighten the engine mount-to-front cover nuts to 50 N·m (37 lb ft).

•	Tighten the engine mount-to-midrail bracket nuts to 50 N·m (37 lb ft).




20. Install the airbox assembly and attaching screws. Install the resonator and push in the plastic fastener.

Tighten
Tighten the air cleaner/resonator attachment bolts (all) to 10 N·m (89 lb in).





Notice: Whenever a throttle cable assembly is installed, make sure the locking tangs are engaged to the front of dash and the seal is properly installed. The cable should be installed so that the tangs are in a horizontal position to provide optimum sealing. Pull on the cable to ensure the tangs are engaged.

21. Connect the electrical connector at the intake air temperature (IAT) sensor.



22. Install the cable retainer into the support bracket until the locking tang is engaged.
23. Connect the accelerator cable to the throttle lever.



24. Raise the vehicle.
25. Install the intake manifold brace to the intake manifold.

Tighten
Tighten the intake manifold support bracket-to-intake manifold (LL0) to 6.5 N·m (58 lb in).




26. Remove the support block.
27. Install the cylinder block drain plugs and close the radiator drain.

Tighten
Tighten the cylinder block drain plugs to 35 N·m (26 lb ft).

28. Lower the vehicle.
29. Fill the cooling system with coolant. Use DEX-COOL™ coolant.
30. Connect the negative battery terminal.

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

31. Prime the fuel system.

31.1.

Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.

31.2.

Repeat the previous step twice.

31.3.

Crank the engine until it starts. Maximum starter motor cranking time is 20 seconds.

31.4.

If the engine does not start, repeat the previous three steps.

32. Start the engine and check for leaks.
33. Fill the cooling system surge bottle to the cold full line. Inspect the coolant level after the engine has run for 2-3 minutes.



34. Install the air cleaner tube and the air box cover.
35. Attach the fresh air hose to the air cleaner tube.