2007 Saturn Relay 3.9 1FACTORY OEM SERVICE PROCEDURE

Installation Procedure

IMPORTANT: DO NOT reuse the throttle body gasket. Install a NEW gasket during assembly.
    Fig 1: Locating Throttle Body, Bolts & Nuts
    GM1614648Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW throttle body gasket. Align the locating tab of the gasket with the notch in the manifold.
  2. Position the throttle body to the intake manifold.
    3. NOTE: Refer to Fastener Notice .
  3. Install the throttle body bolts/nuts.

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

    4. Fig 2: Identifying Heater Inlet & Outlet Hose/Pipes
    GM1675739Courtesy of GENERAL MOTORS CORP.
  4. Position the heater inlet and outlet hose/pipe (2, 3).
  5. Position the heater inlet and outlet hose clamps at the engine pipes.
  6. Install the heater inlet and outlet pipe clip nuts (1) to the throttle body studs.

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

    7. Fig 3: Locating EVAP & ETC Electrical Connectors
    GM1675738Courtesy of GENERAL MOTORS CORP.
Chapter Navigation
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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.