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Home >> Saturn >> 2006 >> Relay 3.9 1, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Mechanical - 3.5L) >> Repair Instructions - On Vehicle >> Lower Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Lower Intake Manifold Gaskets & Seals
    GM61820Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: All gasket-mating surfaces need to be free of oil and foreign material. Use cleaner to clean the surfaces. Refer to Sealers, Adhesives, and Lubricants  for the correct part number.
  1. Install the lower intake manifold gaskets.
  2. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
    3. Fig 2: Installing Lower Intake Manifold
    GM1313742Courtesy of GENERAL MOTORS CORP.
  3. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer to the 4 corners of the intake manifold to block joints (1). Refer to Sealers, Adhesives, and Lubricants  for the correct part number.
  4. Install the lower intake manifold.
    5. Fig 3: Lower Intake Manifold Bolt Tightening Sequence
    GM187067Courtesy of GENERAL MOTORS CORP.
    NOTE: Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.
    NOTE: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.
  5. Apply sealer to the lower intake manifold bolt threads. Refer to Sealers, Adhesives, and Lubricants  for the correct part number.
    6. NOTE: Refer to Fastener Notice .
  6. Install the new lower intake manifold bolts, if applicable, in sequence.

    Tighten: 

    1. Tighten the lower intake manifold bolts in sequence to 13 N.m (115 lb in) on the first pass.
    2. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft) on the final pass.
    3. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.

    7. Fig 4: View Of Heater Inlet Pipe & Nut
    GM523326Courtesy of GENERAL MOTORS CORP.
  7. Install the heater inlet pipe.
  8. Install the heater inlet pipe nut.

    Tighten:  Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).

    9. Fig 5: Locating Thermostat
    GM187058Courtesy of GENERAL MOTORS CORP.
  9. Install the thermostat.
    10. Fig 6: Installing Water Outlet Bolts
    GM1239041Courtesy of GENERAL MOTORS CORP.
  10. Install the water outlet bolts. Refer to Engine Coolant Thermostat Replacement (RPO LX9) or Engine Coolant Thermostat Replacement (RPO LZ9) .
    11. Fig 7: Installing ECT Sensor
    GM1275978Courtesy of GENERAL MOTORS CORP.
  11. Install the ECT sensor.

    Tighten:  Tighten the ECT sensor to 20 N.m (15 lb ft).

    12. Fig 8: Thermostat Bypass Hose At Thermostat Bypass Pipe & Lower Intake Manifold Pipe
    GM190522Courtesy of GENERAL MOTORS CORP.
  12. Connect the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
  13. Connect the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement (LX9) or Radiator Inlet Hose Replacement (LZ9) .
  14. Connect the heater inlet pipe and heater hose to the lower intake manifold.
  15. Install the power steering pump to the front engine cover.
    16. Fig 9: Removing Fuel Rail With Injectors
    GM190516Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel injector rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
    17. Fig 10: Installing Vacuum Hoses
    GM1239037Courtesy of GENERAL MOTORS CORP.
  17. Connect the fuel feed pipe to the fuel injector rail.
    18. Fig 11: MAP Sensor Wiring Harness
    GM190518Courtesy of GENERAL MOTORS CORP.
  18. Connect the fuel injector and MAP wiring harness.
  19. Connect the ECT wiring harness.
  20. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right Side .
  21. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side .
  22. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
  23. Connect the battery ground negative cable. Refer to Battery Negative Cable Disconnection and Connection .
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