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Home >> Saturn >> 2004 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 7 (Engine Mechanical) >> Repair Instructions >> On-Vehicle Repair Instructions >> Intake Manifold Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion 3, 2004 Saturn Ion 2, and 2004 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).
  2. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls - 2.2L (L61).
  3. Disconnect the PCV hose.
  4. Disconnect the purge solenoid tube.
  5. Disconnect the brake booster hose.
  6. Remove the oil level indicator tube bolt.
  7. Remove the fuel rail. Refer to Fuel Rail Assembly Replacement in Engine Controls - 2.2L (L61).
  8. Disconnect the knock sensor electrical connector.
  9. Remove the knock sensor harness connector from the intake manifold.
    10. Fig 1: View Of Knock Sensor Connector
    GM630348Courtesy of GENERAL MOTORS CORP.
  10. Remove the intake manifold nuts and bolts.
  11. Remove the intake manifold.
    12. Fig 2: View Of Intake Manifold
    GM412135Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The intake manifold gasket is reusable, only replace the gasket if damage has occurred.
  12. If applicable, remove the intake manifold gasket.
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