GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 VUE - AWD 🢒 Engine 🢒 Engine Controls and Fuel - 3.5L 🢒 Upper Intake Manifold Replacement

Removal Procedure

    Object Number: 1608799 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling.
  4. Remove the positive crankcase ventilation (PCV) fresh air tube. Refer to Plastic Collar Quick Connect Fitting Service.

    5. Object Number: 1608801 Size: SH
  5. Remove the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service.

    6. Object Number: 1608820 Size: SH
  6. Remove the vacuum hose from the intake manifold.

    7. Object Number: 1608325 Size: SH
  7. Reposition the heater inlet and outlet hose/pipe clamps at the engine pipes.
  8. Remove the heater inlet and outlet hose/pipe clamp nuts from the throttle body studs.
  9. Remove the heater inlet and outlet hoses/pipes from the engine pipes and the throttle body studs.
  10. Reposition the hoses/pipes out of the way.

    11. Object Number: 1608869 Size: SH
  11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).

    12. Object Number: 1608290 Size: SH
  12. Disconnect the evaporative emission (EVAP) canister purge solenoid electrical connector (1).
  13. Disconnect the chassis EVAP line quick connect fitting from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  14. Disconnect the electronic throttle control (ETC) electrical connector (2).

    15. Object Number: 1608802 Size: SH
  15. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  16. Disconnect the left side spark plug wires from the spark plugs.
  17. Disconnect the left side spark plug wires from the ignition coil.
  18. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
  19. Remove the left side spark plug wires.

    20. Object Number: 1608805 Size: SH
  20. Remove the throttle body bolts and nuts.
  21. Remove the throttle body and gasket.

    22. Object Number: 1608814 Size: SH
  22. Remove the MAP sensor bracket bolts.
  23. Remove the MAP sensor bracket and sensor.

    24. Object Number: 1608816 Size: SH
  24. Remove the ignition coil bracket (to intake manifold) bolts.
  25. Remove the intake manifold cover ball stud nut from the intake manifold stud.
  26. Remove the upper intake manifold bolts and stud.
  27. Separate and remove the upper intake manifold from the lower intake manifold.
  28. Remove the upper to lower intake manifold gaskets.
  29. Clean the upper intake to lower intake gasket mating surfaces.

Installation Procedure

    Object Number: 1608816 Size: SH
  1. Install NEW upper to lower intake manifold gaskets.
  2. Install the upper intake manifold onto the lower intake manifold.
  3. Apply threadlock to the upper intake manifold bolts/stud threads. Refer to Adhesives, Fluids, Lubricants, and Sealers.

    4. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the upper intake manifold bolts and stud and tighten to 25 N·m (18 lb ft).
  5. Install the intake manifold cover ball stud nut to the intake manifold stud and tighten the nut to 5 N·m (44 lb in).
  6. Install the ignition coil bracket (to intake manifold) bolts and tighten to 25 N·m (18 lb ft).

    7. Object Number: 1608814 Size: SH
  7. Install the MAP sensor and bracket.
  8. Install the MAP sensor bracket bolts and tighten to 25 N·m (18 lb ft).

    9. Object Number: 1608810 Size: SH
  9. Install the EVAP canister purge solenoid valve.
  10. Install the EVAP canister purge solenoid valve bolt and tighten to 16 N·m (12 lb ft).

    11. Object Number: 1608805 Size: SH
  11. Inspect the throttle body seal for damage, replace as necessary.
  12. Apply threadlock to the throttle body bolts/studs threads. Refer to Adhesives, Fluids, Lubricants, and Sealers.
  13. Position the throttle body gasket and throttle body to the intake.
  14. Install the throttle body bolts and nuts and tighten to 10 N·m (89 lb in).

    15. Object Number: 1608802 Size: SH
  15. Install the left side spark plug wires.
  16. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
  17. Connect the left side spark plug wires to the ignition coil.
  18. Connect the left side spark plug wires to the spark plugs.
  19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.

    20. Object Number: 1608290 Size: SH
  20. Connect the EVAP canister purge solenoid electrical connector (1).
  21. Connect the chassis EVAP line quick connect fitting to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  22. Connect the ETC electrical connector (2).

    23. Object Number: 1608869 Size: SH
  23. Connect the MAP sensor electrical connector (1).

    24. Object Number: 1608325 Size: SH
  24. Position the hoses/pipes.
  25. Install the heater inlet and outlet hoses/pipes to the engine pipes and the throttle body studs.
  26. Install the heater inlet and outlet hose/pipe clamp nuts to the throttle body studs and tighten the nuts to 10 N·m (89 lb in).
  27. Position the heater inlet and outlet hose/pipe clamps at the engine pipes.

    28. Object Number: 1608820 Size: SH
  28. Install the vacuum hose to the intake manifold.

    29. Object Number: 1608801 Size: SH
  29. Install the PCV foul air tube. Refer to Plastic Collar Quick Connect Fitting Service.

    30. Object Number: 1608799 Size: SH
  30. Install the PCV fresh air tube. Refer to Plastic Collar Quick Connect Fitting Service.
  31. Fill the cooling system. Refer to Cooling System Draining and Filling.
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  33. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.