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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 >> Upper Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Removing/Installing Vacuum Hoses
    GM909586Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the vacuum hoses from the following:
    • Evaporative emissions (EVAP) canister purge valve
    • Manifold vacuum source
    • Brake booster
    • Heater and air conditioning (A/C) source
  3. Disconnect the electrical connectors from the following:
    • Exhaust gas recirculation (EGR) valve
    • Mass air flow (MAF) sensor
    • Intake air temperature (IAT) sensor
    • Electronic throttle control
    • EVAP canister purge valve
  4. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
  5. Drain 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.
  6. Remove the left side spark plug wires from the spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 3.5L.
  7. Remove the following wiring harnesses from the retainers:
    • Camshaft position (CMP) sensor wiring harness
    • Left side spark plug wire harness
    • Engine wiring harness
    8. Fig 2: Removing/Installing Upper Intake Manifold Bolts And Stud
    GM1239040Courtesy of GENERAL MOTORS CORP.
  8. Remove the ignition coil bracket with the coils. Refer to Ignition Control Module Replacement in Engine Controls - 3.5L.
  9. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls - 3.5L.
  10. Remove the manifold absolute pressure (MAP) sensor and the bracket. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 3.5L.
  11. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.5L.
  12. Remove the upper intake manifold bolts and the stud.
  13. Remove the upper intake manifold.
  14. Remove the upper intake manifold gaskets.
    15. Fig 3: Removing/Installing Throttle Body
    GM1239002Courtesy of GENERAL MOTORS CORP.
  15. If replacing the upper intake manifold, remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 3.5L.
  16. Clean the upper intake gasket mating surfaces.
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