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Installation Procedure

WARNING: This page is about a different car, the 2005 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing & Installing Intake Manifold
    GM896462Courtesy of GENERAL MOTORS CORP.
  1. Remove the masking from the intake ports.
  2. Install the manifold gaskets.
  3. Install the manifold spacer.
  4. Install the manifold spacer bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

    Tighten:  Tighten the intake manifold spacer bolt to 20 N.m (15 lb ft).

  5. Install the intake manifold gaskets.
  6. Install the intake manifold.
  7. Install the intake manifold bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

    Tighten:  Tighten the intake manifold bolt to 20 N.m (15 lb ft).

    8. Fig 2: Removing & Installing Fuel Rail Assembly
    GM896453Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel injector electrical harness and connectors.
  9. Install the fuel rail.

    Tighten:  Tighten the fuel rail bolts to 8 N.m (71 lb in).

    10. Fig 3: Removing & Installing Intake Plenum
    GM896435Courtesy of GENERAL MOTORS CORP.
  10. Connect the fuel supply hose.
  11. Connect the fuel return hose.
  12. Install the upper intake plenum.
  13. Install the plenum bolts and EGR manifold bolt.

    Tighten: 

    • Tighten the intake plenum bolts to 8 N.m (71 lb in).
    • Tighten the EGR manifold bolt to 8 N.m (71 lb in).

  14. Install the intake plenum clamp using the J 43914  .
  15. Connect the negative battery cable.

    Tighten:  Tighten the battery terminal bolts to 17 N.m (13 lb ft).

  16. Crank the engine but do not start. Check for fuel leaks.
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