GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 L300/LW300 🢒 Engine 🢒 Engine Mechanical - 2.2L (L61) 🢒 Intake Manifold Replacement

Removal Procedure
  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 Injection Fuel Rail Assembly Replacement in Engine Controls -2.2L (L61).
  8. Disconnect the knock sensor electrical connector.

    9. Object Number: 630348 Size: SH
  9. Remove the knock sensor harness connector from the intake manifold.

    10. Object Number: 412135 Size: SH
  10. Remove the intake manifold nuts and bolts.
  11. Remove the intake manifold.

    12. Important: The intake manifold gasket is reusable, only replace the gasket if damage has accrued.

  12. If applicable, remove the intake manifold gasket.

Installation Procedure
  1. If applicable, install the intake manifold gasket.
  2. Install the intake manifold.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


    Object Number: 412135 Size: SH
  3. Install the intake manifold nuts and bolts.

    4. Tighten
    Tighten the intake manifold nuts and bolts to 10 N·m (89 lb in).


    Object Number: 630348 Size: SH
  4. Install the knock sensor harness connector to the intake manifold.
  5. Connect the knock sensor electrical connector.
  6. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.2L (L61).
  7. Install the throttle body.
  8. Install the oil level indicator tube bolt.

    9. Tighten
    Tighten the oil level indicator tube bolt to 10 N·m (89 lb in).

  9. Connect the brake booster hose.
  10. Connect the purge solenoid tube.
  11. Connect the PCV hose.
  12. Install the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls -2.2L (L61).
  13. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls -2.2L (L61).