Installation

CAUTION: WHENEVER FUEL LINE CONNECTS ARE DISCONNECTED, LUBRICATE STEEL LINE MALE ENDS WITH CLEAN ENGINE OIL. HOLDING STEEL LINE, FIRMLY PRESS ON FEMALE CONNECTOR UNTIL CLICK IS HEARD, THEN PULL BACK TO CONFIRM ENGAGEMENT. MAKE SURE THE FUEL LINE CONNECTS ARE FULLY SEATED. PINCHED, KINKED OR DAMAGED FUEL LINES MUST BE REPLACED.

IMPORTANT: Make sure cylinder head and intake manifold gasket sealing surfaces are clean. Use Saturn P/N 21485276 (Loctite 290 or equivalent) to seal a new coolant deaeration tube elbow into the manifold if necessary.


INSTALLATION
1. Install new intake manifold gasket.
2. Install [1][2]intake manifold onto attaching studs.
3. Install [1][2]intake manifold attaching nuts.
4. In sequence, torque the [1][2]intake manifold attaching nuts.

Torque to: 30 NM (22 ft. lbs)

^ [1][2]Intake manifold bolt tightening sequence:

Upper Side
5-2-3
7-4-1-6
Lower Side

5. Install power steering pump assembly and brackets.

Torque to: 38 NM (28 ft. lbs)

6. Install accessory drive belt. Make sure belt is properly aligned on the pulleys.
7. Connect heater and deaeration hoses to [1][2]intake manifold outlets.
8. Install [1][2]intake manifold support brackets.

Torque:
^ R/H to Block 55 NM (41 ft. lbs)
^ L/H to Block 30 NM (22 ft. lbs)
^ Support Brackets-to-Manifold 30 NM (22 ft. lbs)

9. Connect fuel supply line to fuel rail. Install fuel line clip bolt.

Torque to: 4 NM (36 in. lbs)

NOTICE: When the throttle cable is removed, make sure the locking tangs are fully engaged when assembled if disconnected.

Description:

10. Connect throttle cable to throttle body, and throttle cable support bracket. Attach the accelerator control cable bracket.

Torque to: 25 NM (19 ft. lbs)

IMPORTANT: Make sure to confirm positive engagement of electrical connectors and vacuum hoses.

Description:

11. Install the following electrical harness connectors and vacuum hoses.
a. Electrical Connectors:
^ Idle air control (IAC)
^ Throttle position (TP) sensor
^ Manifold absolute pressure (MAP) sensor
^ Fuel injectors (4)
^ EGR valve
b. Vacuum Hoses:
^ [1][2]EVAP Cannister purge solenoid
12. Install PCV valve hose.
13. Install air inlet tube and air filter cover connecting fresh air hose at cam cover.
14. Connect negative battery terminal.
15. With engine off and ignition on, pressurize the fuel system and check for fuel leaks.
16. Install cylinder block drain plugs and close radiator drain.

Torque to: 35 NM (26 ft. lbs)

17. Fill with coolant. Use only a non-phosphate ethylene glycol-based antifreeze.

IMPORTANT: Vehicle must be level when filling coolant.

18. Prime fuel system.
a. Cycle ignition on for five seconds and then off for 10 seconds.
b. Repeat step 18a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds.)
d. If engine does not start, repeat steps 18a - 18c.
19. Start engine and check for leaks.
20. Fill the cooling system surge bottle to the cold full line. Check coolant level after the engine has run for two to three minutes.