GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 RELAY Ext. 🢒 Preface 🢒 Cautions and Notices 🢒 Air Cleaner Assembly Replacement

Removal Procedure
  1. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  2. Remove the left front sheet metal diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
  3. Remove the air cleaner side cover and the air cleaner element. Refer to Air Cleaner Element Replacement .

    4. Object Number: 1404634 Size: SH
  4. Remove the air cleaner upper cover bolts and the air cleaner upper cover.
  5. Remove and reposition the powertrain control module (PCM) with the wiring harness.

    6. Object Number: 1404635 Size: SH
  6. Remove the air cleaner bolts and the air cleaner.

Installation Procedure

    Object Number: 1404635 Size: SH
  1. Install the air cleaner.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the air cleaner bolts.

    3. Tighten
    Tighten the air cleaner bolts to 10 N·m (89 lb in).

  3. Install the PCM and the wiring harness to the air cleaner.
  4. Install the air cleaner side cover and element. Refer to Air Cleaner Element Replacement .

    5. Object Number: 1404634 Size: SH
  5. Install the air cleaner upper cover and the upper cover bolts.

    6. Tighten
    Tighten the air cleaner upper cover bolts to 4 N·m (35 lb in).

  6. Install the left front sheet metal diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
  7. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.