Saturn VUE L81
1. Disconnect negative battery cable.
2. Loosen clamp at air cleaner assembly and throttle body assembly.
3. Remove attachment bolts from outlet resonator/duct assembly to support bracket.
4. Remove outlet resonator/duct assembly.
5. Cover throttle body opening with a shop towel and use shop air to remove any dirt at the base of the throttle body.
Notice:
Damaged or broken throttle body connector retainer clips may result with intermittent electrical connection and (MIL) Service Engine Soon Telltale Lamp or Reduced Power Lamp illuminating.
6. Disconnect throttle body electrical connector.
7. Disconnect Positive Crankcase Ventilation (PCV) fresh air hose at throttle body.
8. Remove purge and PCV vacuum lines.
9. Clamp coolant inlet and outlet hoses with pinch-off tool to avoid leaking coolant on engine.
10. Remove coolant hoses at throttle body.
11. Remove throttle body bolts
Notice:
Cover the intake manifold opening with a shop towel whenever the throttle body is removed to prevent foreign material entry.
12. Remove throttle body.
13. Remove throttle body gasket.
14. Install new throttle body gasket, P/N 24446587.
15. Install new throttle body assembly, P/N 24446586.
Notice:
Use care when tightening throttle body bolts. Manifold damage will result if over torqued.
16. Tighten throttle body bolts.
Tighten
Tighten the Throttle Body-to-Intake Manifold
Bolts - L81 to 7.5 N.m (66 in-lbs).
17. Install throttle body harness retainer, P/N 22729513, to throttle body motor.
18. Position stand off clip inline with throttle body connector.
19. Attach coolant hoses to throttle body assembly.
20. Remove hose pinch-of-tool to allow coolant flow to throttle body.
21. Connect PCV fresh air and vacuum lines.
22. Remove engine harness from metal harness retainer on intake manifold.
23. Remove tape and conduit 457.2 mm (18 in) from throttle body connector.
24. Ensure green terminal retainers of new throttle body connector, P/N 22720050, are in released position to insert terminals.
25. Cut Ckt 581 YEL terminal # 1 throttle body connector 101.6 mm (4 in) from connector on engine harness.
26. Remove insulation from end of cut wire. Recommended strip length is 9.5 mm (3/8 in).
27. Install splice sleeve included in terminal lead, P/N 22690873, by positioning stripped end of engine harness Ckt 581 into sleeve until wire hits stop in center of the splice sleeve.
28. Hand crimp sleeve using the approved crimping tool (found in terminal repair kit J-44020). Gently tug on wires to make sure they are secure.
29. Cut new terminal lead, P/N 22690873, to 101.6 mm (4 in) and insert in terminal location # 1 of new throttle body connector, P/N 22720050.
30. Remove insulation from end of cut wire 9.5 mm (3/8 in) and insert stripped end in splice sleeve for Ckt 581.
31. Hand crimp sleeve to new replacement wire for Ckt 581. Gently tug on wires to make sure they are secure prior to applying heat.
32. Cut Ckt 582 BRN terminal # 4 throttle body connector 127 mm (5 in) from connector.
33. Cut new terminal lead, P/N 22690873 to 127 mm (5 in) and insert terminal location # 4 of throttle body connector, P/N 22720050.
34. Repeat above crimping procedure for Ckt 582.
35. Cut Ckt 2752 BLK terminal # 2 throttle body connector 254 mm (10 in) from connector.
36. Cut new terminal lead, P/N 22690873, to 254 mm (10 in) and insert in terminal location # 2 of throttle body connector, P/N 22720050.
37. Repeat above crimping procedure for Ckt 2752.
38. Cut Ckt 2701 GRA terminal # 3 throttle body connector 304 mm (12 in) from connector.
39. Cut new terminal lead, P/N 22690873, to 304 mm (12 in) and insert in terminal location # 3 of throttle body connector, P/N 22720050.
40. Repeat above crimping procedure for Ckt 2701.
41. Cut Ckt 486 PPL terminal # 5 throttle body connector 355.6 mm (14 in) from connector.
42. Cut new terminal lead, P/N 22690873, to 355.6 mm (14 in) and insert in terminal location # 5 of throttle body connector, P/N 22720050.
43. Repeat above crimping procedure for Ckt 486.
44. Cut Ckt 485 DK GRN terminal # 6 throttle body connector 406.4 mm (16 in) from connector.
45. Cut new terminal lead, P/N 22690873, to 406.4 mm (14 in) and insert in terminal location # 6 of throttle body connector, P/N 22720050.
46. Repeat above crimping procedure for Ckt 485.
Caution:
DO NOT USE MATCH OR OPEN FLAME TO APPLY HEAT TO SEAL.
47. Apply heat using a heat gun, or equivalent, and heat to 175°C (347°F) until glue flows down around edges of sleeves for each ckt.
48. Move terminal retainers of new throttle body connector, P/N 22720050, to locked position to secure terminals.
49. Wrap wires with tape and insert into conduit.
50. Apply tape to conduit to retain wires.
51. Install engine harness in metal harness retainer on intake manifold.
Notice:
Damaged or broken throttle body connector retainer clips may result with intermittent electrical connection and (MIL) Service Engine Soon Telltale Lamp or Reduced Power Lamp illuminating.
52. Connect throttle body electrical connector.
53. Insert throttle body harness into throttle body harness retainer, P/N 22729513, on throttle body motor.
54. Install outlet resonator/duct assembly into position.
55. Tighten clamp at throttle body assembly.
56. Position outlet resonator/duct assembly to support bracket and install bolts.
Tighten
Tighten the Outlet Resonator/Duct Assembly-to-Support Bracket Bolts - L81 to 10 N.m (89 in-lbs).
57. Tighten clamp at air cleaner assembly.
58. Connect negative battery cable.
Tighten
Tighten the Battery Terminal Bolt to 17 N.m (13 ft-lbs).
Important:
Do not depress the accelerator pedal assembly during the automatic relearn procedure.
59. The automatic relearn procedure must be completed by the engine control module (ECM).
60. To complete this relearn procedure, turn ignition to "RUN" position for one minute.
^ Ignition "ON", engine "OFF" for longer than 29 seconds
^ Make sure these engine operating parameters are met before proceeding:
- ECT between 5° and 100° C (41° and 212° F)
- IAT greater than 50° (41° F)
- Ignition voltage above 10 volts.
- Accelerator pedal angle is less than 15%.
61. Verify proper coolant level and add if necessary.