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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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    IMPORTANT: This engine uses a sequential multiport fuel injection system. Injector wiring harness connectors must be connected to their appropriate fuel injector or exhaust emissions and engine performance may be seriously affected.
  1. Disconnect the battery ground negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement .
  3. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side .
  4. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right Side .
  5. Disconnect the engine coolant temperature (ECT) wiring harness.
    6. Fig 1: Removing/Installing Fuel Injector And Manifold Air Pressure (MAP) Wiring Harness
    GM909595Courtesy of GENERAL MOTORS CORP.
  6. Disconnect and remove the fuel injector and manifold air pressure (MAP) wiring harness.
  7. Remove the fuel injector rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  8. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition.
  9. Disconnect the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement (LX9) or Radiator Inlet Hose Replacement (LZ9) .
    10. Fig 2: Removing Water Outlet
    GM909572Courtesy of GENERAL MOTORS CORP.
  10. Remove the water outlet.
    11. Fig 3: Locating Thermostat
    GM187058Courtesy of GENERAL MOTORS CORP.
  11. Remove the thermostat.
    12. Fig 4: View Of Lower Intake Manifold & Bolts
    GM54281Courtesy of GENERAL MOTORS CORP.
  12. Remove the lower intake manifold bolts.
  13. Remove the lower intake manifold.
  14. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
    15. Fig 5: View Of Lower Intake Manifold Gaskets & Seals
    GM61820Courtesy of GENERAL MOTORS CORP.
  15. Remove the lower intake manifold gaskets and seals.
  16. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
  17. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
  18. Remove all the loose room temperature vulcanizing sealer (RTV) (1).
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