Installation

CAUTION: WHENEVER FUEL LINE CONNECTORS ARE DISCONNECTED, LUBRICATE STEEL LINE MALE ENDS WITH CLEAN ENGINE OIL. HOLDING STEEL LINE, FIRMLY PRESS ON FEMALE COUPLER UNTLL A 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 air intake manifold gasket sealing surfaces are clean. Use Saturn P/N 21485276 (Loctite 290 or equivalent) to seal a PCV valve inlet tube into the manifold if replaced.
^ Replace plastic fuel retainer whenever the fuel supply is disconnect at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

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
8-4-1-5
7-3-2-6-9
Lower Side

5. Install power steering pump assembly.

Torque to: 38 NM (27 ft. lbs)

6. Install accessory drive belt. Make sure belt is properly aligned on the pulleys.
7. Connect the heater hose at [1][2]intake manifold outlets. Make sure it is firmly seated.

8. Connect fuel supply line and fasten fuel line clip to brace.

Torque Fuel line clip bolt: 4 NM (36 in. lbs)

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

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

Torque to: 30 NM (22 ft. lbs)

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

10. 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
b. Vacuum Hoses:
^ [1][2]EVAP Cannister purge solenoid
11. Install PCV valve hose.
12. Install air inlet tube, connecting fresh air hose at cam cover. Refer to "Air Induction System" in this section.
13. Connect negative battery terminal.
14. With engine off and ignition on, pressurize the fuel system and check for fuel leaks.
15. Install cylinder block drain plugs and close radiator drain.

Torque to: 35 NM (26 ft. lbs)

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

IMPORTANT: Vehicle must be level when filling coolant.

17. Prime fuel system.
a. Cycle ignition on for five seconds and then off for 10 seconds.
b. Repeat step 17a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat steps 17a -17e.
18. Start engine and check for leaks.
19. Fill the cooling system surge bottle to the cold full line. Check coolant level after the engine has run for two to three minutes.