2005 Saturn Relay AWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: Removing/Installing Throttle Body
    GM1239002Courtesy of GENERAL MOTORS CORP.
  1. Install a new gasket, if necessary.
  2. Install the throttle body assembly.
  3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the throttle body nuts and the bolts.

    Tighten:Β  Tighten the nuts and the bolts to 10 N.m (89 lb in).

  5. Fig 2: Removing/Installing Heater Pipe Nut At Throttle Body
    GM1239021Courtesy of GENERAL MOTORS CORP.
  6. Install the heater inlet pipe. Refer to Heater Hose/Pipe Replacement - Inlet/Outlet in Heating, Ventilation and Air Conditioning.
  7. Install the heater pipe nut to the throttle body.

    Tighten:Β  Tighten the nut to 25 N.m (18 lb ft).

  8. Fig 3: Identifying Electronic Throttle Control (ETC) Electrical Connector & Throttle Body
    GM1544723Courtesy of GENERAL MOTORS CORP.
  9. Connect the ETC electrical connector (1) to the throttle body (2).
  10. Install the air cleaner intake duct. Refer to Air Cleaner Intake Duct ReplacementΒ .
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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