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    1996 Saab 900S 2.3L EFI DOHC 4cyl

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    PT Cruiser, 2001 - 2005

    Intake Manifold

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    Removal & Installation



    Lower Manifold

    NOTE
    The engines in these vehicles are equipped with either an aluminum or plastic manifold.

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Drain the coolant system.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Inlet Air Temperature (IAT) sensor and make-up hose
       
      Air cleaner
       
      Upper intake manifold
       
      Upper radiator hose and coolant outlet connector
       
      Fuel supply line quick-connect from the fuel rail
       
      Fuel injector wiring harness
       
      Oil dipstick tube from the lower intake manifold
       
      Intake manifold and discard the gaskets and seals
       

    8.  
    9. Thoroughly clean the gasket mating surfaces.
    10.  

    To install:

    Click image to see an enlarged view

    Fig. Install new seals on the lower intake manifold-Non-Turbo models



    Click image to see an enlarged view

    Fig. Lower intake manifold bolt torque sequence

    1. Install or connect the following:

      New seals on Non-Turbo models
       
      Intake manifold and torque the bolts in sequence to 105 inch lbs. (12 Nm) on Non-Turbo models
       
      New gaskets on turbo models
       
      Intake manifold. If equipped with an aluminum manifold, torque the bolts in sequence to 250 inch lbs. (28 Nm). If equipped with a plastic manifold, torque the bolts in sequence to 150 inch lbs. (12 Nm) on turbo models.
       
      Lower intake manifold support bracket retainers on turbocharged models to 40 ft. lbs. (54 Nm)
       
      Fuel injector wiring harness
       
      Fuel supply line quick-connect to the fuel tube assembly
       
      Oil dipstick tube to the lower intake manifold
       
      Upper radiator hose
       
      Upper intake manifold
       
      IAT sensor
       
      Air cleaner assembly
       
      Negative battery cable
       

    2.  
    3. Fill the coolant system.
    4.  
    5. Pressurize the fuel system.
    6.  
    7. Start the vehicle and check for leaks, repair if necessary.
    8.  

     
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