2005 Saturn Relay AWDFACTORY OEM SERVICE PROCEDURE

Removal Procedure

  1. Remove the air cleaner intake duct. Refer to Air Cleaner Intake Duct Replacement .
    2. Fig 1: Identifying Electronic Throttle Control (ETC) Electrical Connector & Throttle Body
    GM1544723Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the electronic throttle control (ETC) electrical connector (1) from the throttle body (2).
    3. Fig 2: Removing/Installing Heater Pipe Nut At Throttle Body
    GM1239021Courtesy of GENERAL MOTORS CORP.
  3. Remove the heater pipe nut at the throttle body.
  4. Remove only the heater inlet pipe. Refer to Heater Hose/Pipe Replacement - Inlet/Outlet in Heating, Ventilation and Air Conditioning.
    5. Fig 3: Removing/Installing Throttle Body
    GM1239002Courtesy of GENERAL MOTORS CORP.
  5. Remove the nuts and the bolts from the throttle body.
  6. Remove the throttle body assembly.
  7. Remove the throttle body gasket.
    8. NOTE: Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result.
    Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.
  8. Clean and inspect the throttle body gasket mating surfaces.
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:

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