Crank No Start After Backfire or Rough Run/High Idle After Engine Start (Inspect Intake Manifold Pressure Relief Valve for Stuck Open Condition)

Some customers may comment on the engine backfiring while starting then having a no start, start stall, or a high idle after starting.

This condition may be caused by the intake manifold pressure relief valve being stuck open.

Important: The plastic tabs on the valve may not keep the valve fully assembled when removed from the intake manifold due to the spring pressure.

To correct this condition, remove the intake manifold pressure relief valve and remove any burs or plastic flashing on the retaining legs of the valve plate.

1. Release the clamp and disconnect the power brake booster vacuum hose from the intake manifold.
2. Remove the intake manifold tuning valve actuator solenoid assembly.
3. Remove the intake manifold pressure relief valve from the manifold.



4. Disassemble the pressure relief valve into 3 parts (cup, spring, valve plate).



5. Remove burrs, flashing and round the corners of the retaining legs on the valve plate. Check for any sharp edges of metal housing and file smooth.
6. Assemble the pressure relief valve.
7. Ensure the valve plate easily moves and returns to its normal outward resting position after pressing it against the cup.



8. Install the pressure relief valve to the manifold.

Tighten
Tighten the pressure relief valve bolts (2x5Mx10 mm) to 4.4 ± 0.3 N·m (39 ± 2.5 lb in).

9. Install the intake manifold tuning valve actuator solenoid assembly.

Tighten
Tighten vacuum solenoid assembly bolt (1x5Mx12 mm) to 4.4 ± 0.3 N·m (39 ± 2.5 lb in).

10. Install the brake booster vacuum line on the intake manifold and secure clamp.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J0239 (Valve Assembly, Intake Manifold Pressure Relief - R&R or Replace). An "add time" condition is provided to disassemble valve and remove burrs.