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Home >> Saturn >> 2004 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 52 (Engine Mechanical) >> Repair Instructions >> Off-Vehicle Repair Instructions >> Intake Manifold Installation

Intake Manifold Installation

WARNING: This page is about a different car, the 2005 Saturn Ion 3, 2005 Saturn Ion 2, and 2005 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  1. Install the intake manifold studs in the manifold face.

    Tighten:  Tighten the intake manifold studs to 5 N.m (44 lb in).

    2. Fig 1: View Of Intake Manifold Studs
    GM412542Courtesy of GENERAL MOTORS CORP.
  2. Install a new intake manifold gasket on the intake manifold.
  3. Install the intake manifold.
  4. Install the intake manifold bolts and nuts. Follow the tightening sequence.

    Tighten:  Tighten the bolts and nuts to 10 N.m (89 lb in).

    5. Fig 2: Removing & Installing Intake Manifold
    GM746066Courtesy of GENERAL MOTORS CORP.
  5. Lubricate the fuel injector tip insulators with engine oil.
  6. Install new fuel injector tip insulators.
  7. Lubricate the fuel injector oil rings with engine oil.
  8. Install the fuel rail assembly.
  9. Install the fuel rail stud.

    Tighten:  Tighten the stud to 10 N.m (89 lb in).

    10. Fig 3: View Of Fuel Rail Assembly
    GM746065Courtesy of GENERAL MOTORS CORP.
  10. Install a new throttle body gasket.
  11. Install the throttle body and the accelerator control cable bracket.

    Tighten:  Tighten the bolts and nuts to 10 N.m (89 lb in).

    12. Fig 4: Exploded View Of Throttle Body & Accelerator Control Cable Bracket
    GM865331Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the rear metal tab of the EVAP emission canister valve is resting on the power steering pump metal body.
  12. Install the EVAP emission canister valve (2).

    Tighten:  Tighten the EVAP canister valve to 22 N.m (16 lb ft).

    13. Fig 5: View Of EVAP Emission Canister Valve & Tube
    GM836549Courtesy of GENERAL MOTORS CORP.
  13. Install the EVAP emission canister valve tube (1).
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