GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Montana 🢒 Engine 🢒 Engine Controls - 3.4L 🢒 Secondary Air Injection Shutoff Valve Replacement - Bank 1

Removal Procedure
  1. Turn OFF the ignition.

    2. Caution: Allow the engine to cool before servicing the secondary air injection AIR system in order to reduce the chance of severe burns.


    Object Number: 541456 Size: SH
  2. Disconnect the secondary air injection (AIR) crossover pipe from the shut-off valve.

    3. Object Number: 511633 Size: SH
  3. Disconnect the vacuum line from the shut-off valve.

    4. Object Number: 511626 Size: SH
  4. Remove the AIR shut-off valve nut.
  5. Remove the shut-off valve to manifold pipe bolts.
  6. Remove the shut-off valve from the bracket.

Installation Procedure

    Object Number: 511626 Size: SH
  1. Install a new gasket between the shut-off valve and the manifold pipe.
  2. Install the shut-off valve to the bracket.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the AIR shut-off valve to the manifold pipe fasteners.

    4. Tighten
    Tighten the AIR shut-off valve bolts to 20 N·m (15 lb ft).

  4. Install the AIR shut-off valve nut.

    5. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 511633 Size: SH
  5. Connect the vacuum line to shut-off valve.

    6. Object Number: 541456 Size: SH
  6. Connect the AIR crossover pipe to the shut-off valve.
  7. Fasten the quick clamps.