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Saturn Master
2,993 Answers
- Posted on Mar 27, 2009
Re: Intake manifold gasket
Intake Manifold
REMOVAL & INSTALLATION
1.9L SOHC Engine
- Before servicing the vehicle, refer to the precautions in the beginning of this section.
- Properly relieve the fuel system pressure.
- Drain the coolant system.
- Remove or disconnect the following:
- Negative battery cable
- Air cleaner fresh air hose
- Positive Crankcase Ventilation (PCV) valve hose
- Fuel line from the rail
- Throttle cable from the throttle body
- Throttle cable bracket nuts
- Fuel injector electrical connectors
- Throttle Position (TP) sensor electrical connectors
- Idle Air Control (IAC) valve electrical connectors
- Manifold Absolute Pressure (MAP) sensor electrical connectors
- Exhaust Gas Recirculation (EGR) valve electrical connectors
- Heater hose from the intake manifold outlet
- Position the wiring harness over the brake master cylinder
- Remove or disconnect the following:
- Intake manifold support bracket bolt
- Label the vacuum line for proper assembly
- Drive belt
- Power steering pump
- Upper intake manifold bolts
- Evaporative Emissions (EVAP) canister purge valve solenoid vacuum hose
- Brake booster vacuum hose
- Lower intake manifold bolts
- Intake manifold
To install:
- Thoroughly clean all gasket mating surfaces. Be careful not to damage or score the aluminum surface. If replaced, use Loctite® 290, to seal the new PCV valve inlet tube into the manifold.
NOTE: Refer to Section 1 of this manual for the intake manifold torque sequence illustration. The illustration is located after the Torque Specification Chart.
- Install or connect the following:
- New gasket and manifold. Torque the nuts in sequence to 22 ft. lbs. (30 Nm).
- Power steering pump. Torque the fasteners to 27 ft. lbs. (38 Nm).
- Drive belt.
- Heater hose and install the manifold support bracket bolt. Tighten the bolt to 22 ft. lbs. (30 Nm).
- Lubricate the male ends of the fuel lines with a few drops of clean engine oil, then connect the fuel supply and return lines.
- Fuel line(s) in the retaining bracket. Torque the mounting screw to 36 inch lbs. (4 Nm).
- Throttle cable to the throttle body and attach the accelerator cable bracket. Torque the bolts to 22 ft. lbs. (30 Nm).
- Reposition the wiring harness and connect the wiring and vacuum hoses to their original locations. The harness leads to the TP sensor and EGR solenoid must be routed between the intake manifold runners.
- Negative battery cable
- Fill the coolant system.
- Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine.
- Start the engine, check for leaks, and repair if necessary.
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