Wednesday, July 13, 2011

how to replace spark plugs on 2005 Saturn VUE 6 cylinder?

The plugs or wires are not visible from the top or sides of the moter. You have to remove the large black plastic air intake. Then remove the intake manifold (not too hard to do) to access the spark plugs and wires.

Its not that difficult but you have to remove the coils that sit over the spark plugs. They screw off and then you have to twist and pull the rubber spark plug covers. You'll need a spark plug socket and a 6" extension for your socket wrench. Make sure you use anit sieze grease on the spark plugs before you install them as it will prevent them from friezing in the heads.

SPARK PLUG REPLACEMENT
REMOVAL PROCEDURE
NOTE : This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage.
Remove the ignition coils.
Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal.
Inspect the spark plugs. Refer to Spark Plug Inspection.
INSTALLATION PROCEDURE
Gap the spark plug, using round wire type spark plug gap gage. Adjust the spark plug gap to 1.1 mm (0.043 in).
Install the spark plugs with a spark plug socket. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT coat the spark plugs with anti-seize compound. Over torquing could occur and damage to the cylinder head threads may result. Tighten the spark plugs to 18 N.m (13 lb in) .
Install the ignition coils.
--------------------

Saturn Vue V6 engine utilizes six spark plugs, one plug per cylinder. Each spark plug uses a spark plug wire to connect the plug to the electrical ignition system.

once you remove the cover, the process is not much different than most other vehicles.

  • Remove the large black cover from the engine by removing the bolts in each corner with a socket and ratchet. Lift the cover off and set it aside.

  • Locate the spark plug wires. Three go to the front of the engine and three go to the back of the engine. Locate the plug wire that goes to the front right spark plug.

  • Grab the boot (base) of the spark plug wire and pull up on it hard to remove it from the spark plug.

  • Place a spark plug socket onto your ratchet and remove the spark plug by turning it counter-clockwise.

  • Place a small amount of anti-cease compound on the threads of the new spark plug. Thread the spark plug into the hole by hand to avoid cross-threading the plug. Tighten the plug with the spark plug socket and ratchet.

  • Press the boot of the spark plug wire back onto the top of the spark plug until it snaps into place.

  • Place the black plastic cover back onto the top of the engine and secure it using the four bolts removed in Step 1.

  • Complete steps 2 through 5 with the other five spark plugs.---------------------------


    Intake manifold removal procedure:---

    Intake Manifold Replacement

    Tools Required

    J 37088-A Fuel Line Disconnect Set
    J 44095 Fuel Pressure Adapter Fitting
    SA9127E Gauge Bar Set

    Removal Procedure

      Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.


      Object Number: 963963  Size: SH

    1. Disconnect the negative battery cable. .
    2. Loosen the clamp at the air cleaner assembly and throttle body assembly.
    3. Remove the attachment bolts from the outlet resonator/duct assembly to support bracket.
    4. Remove the outlet resonator/duct assembly.
      Object Number: 963185  Size: SH

    5. Remove the resonator outlet duct assembly bracket from the manifold.

      Caution: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.


      Object Number: 952269  Size: SH

    6. Relieve the fuel system pressure. .
    7. Disconnect SA9127E , or equivalent and J 44095 , or equivalent, after the pressure has been relieved.
    8. Disconnect the fuel transfer line at the quick connect from the fuel line using J 37088-A , or equivalent blue tool.
      Object Number: 959866  Size: SH

    9. Disconnect the electrical harness attachment from the manifold and position harness away from the manifold.
      Object Number: 963217  Size: SH

    10. Disconnect the attachment of the purge solenoid and line from the rear of manifold.
    11. Disconnect the brake booster line from the intake manifold.
    12. Disconnect the fuel injector and intake manifold control solenoid connectors.
      Object Number: 959298  Size: SH

    13. Remove the PCV fresh air hose at throttle body.
    14. Remove the throttle body bolts from the throttle body.
    15. Remove the throttle body cooling hose bracket bolts.
    16. With the coolant lines connected to throttle body, lay the throttle body assembly over the mast cylinder.
      Object Number: 959544  Size: SH

      Important: To remove the 5 upper manifold bolts, use a 1/4 inch drive T-30 TORX and long 1/4 inch drive extension.

    17. Remove the upper manifold to spacer plate bolts.
      Object Number: 952138  Size: SH

    18. Remove the lower intake manifold bolt near the throttle body.
    19. Remove the intake manifold assembly.
      Object Number: 946642  Size: SH

    20. Remove the lower intake manifold spacer plate bolts.
      Object Number: 951932  Size: SH

    21. Remove the intake spacer plate.
    22. Seals are re-usable if not damaged. If O-ring seals re being replaced, remove seals from both sides.
      Object Number: 963025  Size: SH

    23. The intake spacer plate has O-ring seals on both sides.
    24. Clean the spacer plate bolt holes and bolts. Remove all thread locked material.

    Installation Procedure


      Object Number: 951932  Size: SH

    1. Transfer all components to the new intake manifold.
    2. Install new O-rings to spacer assembly, if necessary.
      Object Number: 946642  Size: SH

    3. Install the intake manifold spacer plate.

      .

      Important: Do not over torque the intake manifold spacer plate bolts.

    4. Install the 12 intake manifold saver plate bolts. Apply LOCTITE® 242 threadlocker, or equivalent, to the bolts.

      Tighten
      Tighten the bolts to 16 N·m (11 lb ft).


      Object Number: 959544  Size: SH

      Important: Do not over torque the intake manifold bolts.

    5. Install the intake manifold assembly into position.
    6. Install the 5 intake manifold bolts.

      Tighten
      Tighten the bolts to 7.5 N·m (66 lb in).


      Object Number: 945757  Size: SH

    7. Install the throttle body gasket.
    8. Install the throttle body assembly bolts.

      Tighten
      Tighten the throttle body-to-intake manifold bolts to 7.5 N·m (66 lb in).

    9. Connect the PCV fresh air hose at the throttle body.
    10. Install the outlet resonator duct assembly bracket to the manifold and tighten nuts.

      Tighten
      Tighten the outlet resonator duct nuts to 5 N·m (44 lb in).


      Object Number: 963217  Size: SH

    11. Connect the intake manifold control solenoid and injector harnesses.
    12. Connect the electrical harness to the intake bracket near the intake manifold runner control solenoid.
    13. Connect the brake vacuum hose to manifold.

      Important: An audible click noise can be heard when the fuel line is installed. Slightly pull rearward on line to assure the connection is fully seated.

    14. Connect the fuel line to the fuel transfer line.
    15. Connect the purge solenoid and line to intake manifold.
      Object Number: 959866  Size: SH

    16. Attach the electrical harness to rear of manifold.
      Object Number: 963185  Size: SH

    17. Install the outlet resonator duct assembly into position and tighten clamp at the throttle body assembly.
    18. Position the outlet resonator duct assembly to support bracket and install bolts.

      Tighten
      Tighten the outlet resonator duct-to-bracket nuts to 10 N·m (89 lb in).

    19. Tighten the clamp at the air cleaner assembly.
    20. Connect the negative battery cable


    Read more: How do you remove the Intake Manifold on a 2003, 6 cyl, 3.0L - JustAnswer http://www.justanswer.com/saturn/3vwwk-remove-intake-manifold-2003-cyl-3-0l.html#ixzz1S0zGb9CL

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