Intake Manifold: Removal
WARNING: This page is about a different car, the 2003 Saturn Vue and 2002 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
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.
NOTE:
The area near the mating surfaces between the throttle body-to-manifold and manifold-to-cylinder head should be free from loose dirt and foreign material BEFORE servicing.
- Disconnect the negative battery cable. Loosen clamp at the air cleaner assembly and throttle body assembly. Remove the attachment bolts from the outlet resonator/duct assembly-to-support bracket. Remove the outlet resonator/duct assembly. Remove the resonator outlet duct assembly bracket from the manifold.NOTE: 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.
- Relieve the fuel system pressure. See FUEL PRESSURE RELEASE . Disconnect gauge bar set and fuel pressure adapter fitting after the pressure has been relieved.
- Disconnect the fuel transfer line at the quick connect from the fuel line using Fuel Line Disconnect Set (J-37088-A), or equivalent blue tool. Disconnect the electrical harness attachment from intake manifold and position harness aside.
- Disconnect the attachment of the purge solenoid and line from the rear of manifold. Disconnect the brake booster line from the intake manifold. Disconnect the fuel injector and intake manifold control solenoid connectors.
- Remove the Positive Crankcase Ventilation (PCV) fresh air hose at throttle body. Remove the throttle body bolts from the throttle body. Remove the throttle body cooling hose bracket bolts. See Fig 1. With the coolant lines connected to throttle body, lay the throttle body assembly aside.NOTE: To remove the 5 upper manifold bolts, use a 1/4 inch drive T-30 TORX and long 1/4 inch drive extension.
- Remove the upper manifold-to-spacer plate bolts. See Fig 2. Remove the lower intake manifold bolt near the throttle body. See Fig 3.CAUTION: Use care when removing intake manifold from engine to avoid damaging intake manifold or cylinder head.
- Remove the upper intake manifold assembly. Remove the lower intake manifold spacer plate bolts. Remove the intake spacer plate. Seals are re-usable if not damaged. If "O" ring seals are being replaced, remove seals from both sides. The intake spacer plate has "O" ring seals on both sides. Clean the spacer plate bolt holes and bolts. Remove all thread locked material.
- While intake manifold and other component are removed, ensure cylinder head ports are covered to prevent entry of foreign material into cylinder head. Install Debris Screen (J-45482). Block the intake manifold openings to prevent entry of foreign material from entering intake manifold.