GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Engine 🢒 Engine Mechanical - 2.0L (LSJ) 🢒 Intake Manifold Replacement

Removal Procedure

    Object Number: 1339285 Size: SH
  1. Remove the supercharger. Refer to Supercharger Replacement .
  2. Remove the generator. Refer to Generator Replacement .
  3. Drain the charged air cooling system. Refer to Charge Air Cooling System Draining and Filling .
  4. Disconnect the charged air cooling system inlet and outlet hoses.
  5. Remove the charged air coolant pump.
  6. Remove the cooling fan assembly. Refer to Fan Shroud Replacement .
  7. Remove the AC compressor bolts and reposition the compressor to access the oil level indicator tube.
  8. Remove the oil level indicator tube bolt.

    9. Object Number: 1339178 Size: SH

    Important: Be sure to remove all fasteners before attempting to remove the intake manifold.

  9. Remove the intake manifold nuts and bolts.
  10. Remove the intake manifold.

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

  11. If applicable, remove the intake manifold gasket.

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

    3. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1339178 Size: SH
  3. Install the intake manifold nuts and bolts.

    4. Tighten
    Tighten the intake manifold nuts and bolts to 22 N·m (16 lb ft).


    Object Number: 1339285 Size: SH
  4. Install the oil level indicator tube and bolt.

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

  5. Reposition the AC compressor and install the bolts.

    6. Tighten
    Tighten the bolts to 22 N·m (16 lb ft).

  6. Install the cooling fan assembly. Refer to Fan Shroud Replacement .
  7. Install the charged air coolant pump. Refer to Charge Air Cooler Coolant Pump Replacement .
  8. Install the generator. Refer to Generator Replacement .
  9. Connect the charged air cooling system inlet and outlet hoses.
  10. Fill the charged air cooling system. Refer to Charge Air Cooling System Draining and Filling .
  11. Install the supercharger. Refer to Supercharger Replacement .