Saab 2000-06

Intake Manifold

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Removal & Installation



2.0L And 2.3L Engines

CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following: Negative battery cableRubber elbow running between the throttle housing and the turbocharger, if equippedThrottle position sensor connectorHoses at the throttle housingThrottle housingOil filler pipe bracket at the manifold. Position it out of the wayAll hoses and lines attached to the manifold. Label them prior to removalAIC valveFuel line from the pressure regulatorBanjo fitting connecting the fuel line to the fuel railFuel line and pulsatorEach fuel injector electrical leadTemperature sensorGround wires at the manifoldHarness assembly from underneath the manifoldEGR pipe and all connectorsIntake manifold

    Negative battery cable
     
    Rubber elbow running between the throttle housing and the turbocharger, if equipped
     
    Throttle position sensor connector
     
    Hoses at the throttle housing
     
    Throttle housing
     
    Oil filler pipe bracket at the manifold. Position it out of the way
     
    All hoses and lines attached to the manifold. Label them prior to removal
     
    AIC valve
     
    Fuel line from the pressure regulator
     
    Banjo fitting connecting the fuel line to the fuel rail
     
    Fuel line and pulsator
     
    Each fuel injector electrical lead
     
    Temperature sensor
     
    Ground wires at the manifold
     
    Harness assembly from underneath the manifold
     
    EGR pipe and all connectors
     
    Intake manifold
     

  6.  

To install:

  1. Scrape off any excess gasket material
  2.  
  3. Install or connect the following; Intake manifold with a new gasket and torque the bolts in a crisscross pattern to 16 ft. lbs. (22 Nm)Wire harnessEGR pipeGround wiresTemperature sensorInjector leadsFuel line to the pressure regulatorFuel line/pulsator to the fuel rail. Secure it with a plastic tieOil filler pipe bracket to the manifoldAIC valveThrottle housingRubber elbow between the turbocharger and the intake manifold, if equippedNegative battery cable

    Intake manifold with a new gasket and torque the bolts in a crisscross pattern to 16 ft. lbs. (22 Nm)
     
    Wire harness
     
    EGR pipe
     
    Ground wires
     
    Temperature sensor
     
    Injector leads
     
    Fuel line to the pressure regulator
     
    Fuel line/pulsator to the fuel rail. Secure it with a plastic tie
     
    Oil filler pipe bracket to the manifold
     
    AIC valve
     
    Throttle housing
     
    Rubber elbow between the turbocharger and the intake manifold, if equipped
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  


CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Rubber elbow running between the throttle housing and the turbocharger, if equipped
     
    Throttle Position (TP) sensor connector
     
    Hoses at the throttle housing
     
    Throttle housing
     
    Oil filler pipe bracket at the manifold. Position it out of the way.
     
    All hoses and lines attached to the manifold. Label them prior to removal.
     
    Idle Air Control (IAC) valve
     
    Fuel line from the pressure regulator
     
    Banjo fitting connecting the fuel line to the fuel rail
     
    Fuel line and pulsator
     
    Each fuel injector electrical lead
     
    Temperature sensor
     
    Ground wires at the manifold
     
    Harness assembly from underneath the manifold
     
    Exhaust Gas Recirculation (EGR) pipe and all connectors
     
    Intake manifold
     

  8.  

To install:

  1. Scrape off any excess gasket material
  2.  
  3. Install or connect the following;

    Intake manifold with a new gasket and torque the bolts in a crisscross pattern to 16 ft. lbs. (22 Nm)
     
    Wire harness
     
    EGR pipe
     
    Ground wires
     
    Temperature sensor
     
    Injector leads
     
    Fuel line to the pressure regulator
     
    Fuel line/pulsator to the fuel rail
     
    Oil filler pipe bracket to the manifold
     
    IAC valve
     
    Throttle housing
     
    TP sensor connector
     
    Rubber elbow between the turbocharger and the intake manifold, if equipped
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  


CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Rubber elbow running between the throttle housing and the turbocharger, if equipped
     
    Throttle position sensor connector
     
    Hoses at the throttle housing
     
    Throttle housing
     
    Oil filler pipe bracket at the manifold. Position it out of the way
     
    All hoses and lines attached to the manifold. Label them prior to removal
     
    AIC valve
     
    Fuel line from the pressure regulator
     
    Banjo fitting connecting the fuel line to the fuel rail
     
    Fuel line and pulsator
     
    Each fuel injector electrical lead
     
    Temperature sensor
     
    Ground wires at the manifold
     
    Harness assembly from underneath the manifold
     
    EGR pipe and all connectors
     
    Intake manifold
     

  6.  

To install:

  1. Scrape off any excess gasket material
  2.  
  3. Install or connect the following;

    Intake manifold with a new gasket and torque the bolts in a crisscross pattern to 16 ft. lbs. (22 Nm)
     
    Wire harness
     
    EGR pipe
     
    Ground wires
     
    Temperature sensor
     
    Injector leads
     
    Fuel line to the pressure regulator
     
    Fuel line/pulsator to the fuel rail. Secure it with a plastic tie
     
    Oil filler pipe bracket to the manifold
     
    AIC valve
     
    Throttle housing
     
    Rubber elbow between the turbocharger and the intake manifold, if equipped
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

2.8L Engine

CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Plug the intake ducts and blow the intake manifold clean.



    Negative battery cable
     
    Engine cover
     
    Power steering fluid reservoir bolt and place reservoir aside
     
    Connector of intake air sensor (688)
     
    Upper charge air pipe
     
    Throttle body
     
    Ground cable of the control module
     
    Engine control module connectors (608A and 608B)
     
    Engine breather pipe
     
    Cable duct and move it aside
     
    Atmospheric pressure sensor bracket
     
    Injectors' wiring harness bracket
     
    Brake servo pipe from intake manifold
     
    Crankcase ventilation pipes from intake manifold
     
    Upper intake manifold bolts
     
    Upper intake manifold and gaskets
     
    Injectors' wiring harness from engine
     



    Fuel pressure sensor connector.
     

  6.  
  7. Release any fuel pressure by pressing in the needle valve on the fuel rail. Catch any fuel spill with a cloth.

    Fuel line from fuel rail using 83 95 261 Fuel line tool
     
    Lower intake manifold bolts
     
    Lower intake manifold and gaskets
     

  8.  

To install:

  1. Plug the ducts and clean the sealing surfaces. Remove the plugs.
  2.  
  3. Install new gaskets and position the lower intake manifold. Install and tighten the bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. Remove or disconnect the following:

    Fuel line to fuel rail
     
    Fuel pressure sensor connector
     
    Injectors' wiring harness to the engine
     

  6.  
  7. Clean the sealing surfaces and fit new gaskets. Carefully position the upper intake manifold.
  8.  
  9. Install and tighten the upper intake manifold bolts to 17 ft. lbs. (23 Nm).

    Crankcase ventilation pipes to intake manifold and fit bolt
     
    Brake servo pipe to intake manifold
     
    Injectors' wiring harness bracket
     
    Atmospheric pressure sensor bracket
     
    Cable duct.
     
    Engine breather pipe
     
    Engine control module connectors (608A and 608B)
     
    Ground cable of the control module
     
    Throttle body. Tighten throttle body bolts to 7 ft. lbs. (9 Nm).
     
    Charge air pipe
     
    Intake air sensor (688)
     
    Power steering fluid reservoir and fit bolt
     
    Engine cover
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

3.0L Engines
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableEngine coversCruise control cableThrottle cableControl rodIntake tube from the Mass Air Flow (MAF) sensor assemblyVacuum hoses and electrical connectors from MAF assemblyMAF assemblyHoses and wiring from the upper intake manifold. Label prior to removal.Upper intake manifoldIdle Air Control (IAC) valveFuel pressure regulator hoseHarness from under the throttle plate housingInjector electrical harnessCamshaft Position (CMP) sensor connectorFuel line. Plug to prevent contaminationLower intake manifold

    Negative battery cable
     
    Engine covers
     
    Cruise control cable
     
    Throttle cable
     
    Control rod
     
    Intake tube from the Mass Air Flow (MAF) sensor assembly
     
    Vacuum hoses and electrical connectors from MAF assembly
     
    MAF assembly
     
    Hoses and wiring from the upper intake manifold. Label prior to removal.
     
    Upper intake manifold
     
    Idle Air Control (IAC) valve
     
    Fuel pressure regulator hose
     
    Harness from under the throttle plate housing
     
    Injector electrical harness
     
    Camshaft Position (CMP) sensor connector
     
    Fuel line. Plug to prevent contamination
     
    Lower intake manifold
     

  4.  

To install:

  1. Install or connect the following: Lower intake manifold with new gaskets and torque the bolts to 15 ft. lbs. (20 Nm)Fuel linesInjector wiringCMP sensorUpper intake manifold with new gasketsThrottle plate housing and torque the bolts to 15 ft. lbs. (20 Nm)Wiring and hosesIAC valveHose to the fuel pressure regulatorMAF assembly and hosesThrottle control rodCruise control cableEngine coversNegative battery cable

    Lower intake manifold with new gaskets and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Injector wiring
     
    CMP sensor
     
    Upper intake manifold with new gaskets
     
    Throttle plate housing and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Wiring and hoses
     
    IAC valve
     
    Hose to the fuel pressure regulator
     
    MAF assembly and hoses
     
    Throttle control rod
     
    Cruise control cable
     
    Engine covers
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableEngine coversCruise control cableThrottle cableControl rodIntake tube from the Mass Air Flow (MAF) sensor assemblyVacuum hoses and electrical connectors from MAF assemblyMAF assemblyHoses and wiring from the upper intake manifold. Label prior to removal.Upper intake manifoldIdle Air Control (IAC) valveFuel pressure regulator hoseHarness from under the throttle plate housingInjector electrical harnessCamshaft Position (CMP) sensor connectorFuel line. Plug to prevent contaminationLower intake manifold

    Negative battery cable
     
    Engine covers
     
    Cruise control cable
     
    Throttle cable
     
    Control rod
     
    Intake tube from the Mass Air Flow (MAF) sensor assembly
     
    Vacuum hoses and electrical connectors from MAF assembly
     
    MAF assembly
     
    Hoses and wiring from the upper intake manifold. Label prior to removal.
     
    Upper intake manifold
     
    Idle Air Control (IAC) valve
     
    Fuel pressure regulator hose
     
    Harness from under the throttle plate housing
     
    Injector electrical harness
     
    Camshaft Position (CMP) sensor connector
     
    Fuel line. Plug to prevent contamination
     
    Lower intake manifold
     

  4.  


    Click image to see an enlarged view

    Fig. Intake manifold bolt torque sequence-3.0L engine


To install:

  1. Install or connect the following: Lower intake manifold with new gaskets and torque the bolts to 15 ft. lbs. (20 Nm)Fuel linesInjector wiringCMP sensorUpper intake manifold with new gasketsThrottle plate housing and torque the bolts to 15 ft. lbs. (20 Nm)Wiring and hosesIAC valveHose to the fuel pressure regulatorMAF assembly and hosesThrottle control rodCruise control cableEngine coversNegative battery cable

    Lower intake manifold with new gaskets and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Injector wiring
     
    CMP sensor
     
    Upper intake manifold with new gaskets
     
    Throttle plate housing and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Wiring and hoses
     
    IAC valve
     
    Hose to the fuel pressure regulator
     
    MAF assembly and hoses
     
    Throttle control rod
     
    Cruise control cable
     
    Engine covers
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine covers
     
    Cruise control cable
     
    Throttle cable
     
    Control rod
     
    Intake tube from the Mass Air Flow (MAF) sensor assembly
     
    Vacuum hoses and electrical connectors from MAF assembly
     
    MAF assembly
     
    Hoses and wiring from the upper intake manifold. Label prior to removal.
     
    Upper intake manifold
     
    Idle Air Control (IAC) valve
     
    Fuel pressure regulator hose
     
    Harness from under the throttle plate housing
     
    Injector electrical harness
     
    Camshaft Position (CMP) sensor connector
     
    Fuel line
     
    Lower intake manifold
     

  4.  

To install:

Click image to see an enlarged view

Fig. Intake manifold bolt tightening sequence-3.0L engine

  1. Install or connect the following:

    Lower intake manifold with new gaskets and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Injector wiring
     
    CMP sensor
     
    Upper intake manifold with new gaskets
     
    Throttle plate housing and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Wiring and hoses
     
    IAC valve
     
    Hose to the fuel pressure regulator
     
    MAF assembly and hoses
     
    Throttle control rod
     
    Cruise control cable
     
    Engine covers
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine covers
     
    Cruise control cable
     
    Throttle cable
     
    Control rod
     
    Intake tube from the Mass Air Flow (MAF) sensor assembly
     
    Vacuum hoses and electrical connectors from MAF assembly
     
    MAF assembly
     
    Hoses and wiring from the upper intake manifold. Label prior to removal.
     
    Upper intake manifold
     
    Idle Air Control (IAC) valve
     
    Fuel pressure regulator hose
     
    Harness from under the throttle plate housing
     
    Injector electrical harness
     
    Camshaft Position (CMP) sensor connector
     
    Fuel line. Plug to prevent contamination
     
    Lower intake manifold

    Click image to see an enlarged view

    Fig. Intake manifold bolt torque sequence-3.0L engine

     

  4.  

To install:

  1. Install or connect the following:

    Lower intake manifold with new gaskets and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Injector wiring
     
    CMP sensor
     
    Upper intake manifold with new gaskets
     
    Throttle plate housing and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Wiring and hoses
     
    IAC valve
     
    Hose to the fuel pressure regulator
     
    MAF assembly and hoses
     
    Throttle control rod
     
    Cruise control cable
     
    Engine covers
     
    Negative battery cable
     

  2.  

 
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