LEMON Manuals: Even more car manuals for everyone
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 >> Upper Intake Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Removing/Installing Throttle Body
    GM1239002Courtesy of GENERAL MOTORS CORP.
  1. If removed, install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 3.5L.
    2. Fig 2: Removing/Installing Upper Intake Manifold Bolts And Stud
    GM1239040Courtesy of GENERAL MOTORS CORP.
  2. Install the upper intake manifold gaskets.
  3. Install the upper intake manifold.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the right upper intake manifold bolts and the stud.

    Tighten:  Tighten the bolts and the stud to 25 N.m (18 lb ft).

  5. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.5L.
  6. Install the MAP sensor bracket and the sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 3.5L.
  7. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 3.5L.
  8. Install the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement in Engine Controls - 3.5L.
  9. Install the following wiring harnesses to the retainers:
    • Engine wiring harness
    • Left side spark plug wire harness
    • CMP sensor wiring harness
  10. Install the left side spark plug wires to the spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 3.5L.
  11. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
  12. Connect the electrical connectors to the following:
    • EVAP canister purge valve
    • Electronic throttle control
    • IAT sensor
    • MAF sensor
    • EGR valve
    13. Fig 3: Installing Vacuum Hoses
    GM1239037Courtesy of GENERAL MOTORS CORP.
  13. Install the vacuum hoses to the following:
    • Heater and A/C source
    • Brake booster
    • Manifold vacuum source
    • EVAP canister purge valve
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  15. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill LX9) or Cooling System Draining and Filling (Static Fill LZ9) or Cooling System Draining and Filling (Vac-N-Fill) in Engine Cooling.
scientia non olet · About LEMON Manuals