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1. Unclamp the lid of the factory airbox and lift out the original filter element. 2. Remove the black crankcase vent hose from the valve cover by pulling firmly toward the driver’s side of the vehicle. 3. Using a pair of pliers or flat-head screwdriver or 10mm socket (depending on model year,) release the factory clamp around the throttle body, wiggle and pull toward the driver side to remove from the throttle, and remove the plastic factory air tube and lid assembly from the engine compartment. 4. Loosen the three 10mm bolts at the base of the airbox. You should find two in the rear of the airbox (at the front of the battery tray) and one in the right-front corner of the airbox. 5. Unscrew the oxygen temperature sensor from its location. In 95-02 models, the air temp sensor is in the front of the airbox within the airbox inlet tube. In 91-94 models, the air temp sensor is in the intake tube that runs above the radiator near the point of entry into the airbox. This sensor should later be inserted into the fitting located on the front of the Powerstack directly behind the base of the air filter. 6. 1995-02 models will have a baffle box attached to the airbox on the passenger side of the airbox. This needs to be removed before the airbox can be removed. Use a screwdriver to pry out the rivet in the front of the baffle. Then just pull the baffle toward the passenger side and out from the airbox. 7. Lift the airbox out of the engine compartment. 8. Attach the cone-filter to the large end of the Powerstack and clamp it down firmly. Then, attach one end of the silicon coupler (coupler and clamps are provided with your Powerstack kit) to the small end of the Powerstack, leaving about two inches of overhang, and clamp it down firmly. (If you are assembling a PWRSTK03 or PWRSTK04, you will need to connect the two pipe sections using one of the provided couplers. For now, leave the clamps loose so that you can fine-tune the relative pipe positions once you have positioned the kit within the engine compartment.) 9. Maneuver the Powerstack into place and attach the other end of the coupler to the throttle body. Clamp it down firmly and allow the Powerstack to rest in its place. We recommend use of the SPSB002 mounting bracket with PWRSTK01 and PWRSTK02 units to properly locate and secure the front end of the Powerstack. 10. If you are assembling a PWRSTK03 or PWRSTK04 unit, you will need to attach the integral mounting bracket to the EGR valve. Remove the forward bolt from the EGR valve, position the Powerstack mounting arm against the top of the EGR valve, and replace the bolt. Torque to 22ft-lbs. 11. If you are assembling a PWRSTK03 or PWRSTK04 unit, you may need to fine-tune the relative position of the pipe sections to ensure satisfactory fitment. Once you are satisfied with the pipe routing, then tighten the clamps to secure the pipe halves together. 12. Attach the silicon hose between the Powerstack nozzle and the valve cover. You can also use the optional KN62-1000 or KN62-2470 filter to vent the crankcase and install a vacuum cap onto the Powerstack nozzle. 13. Insert the Saturn air temperature sensor into the fitting in the front of the Powerstack. Some 95-02 models have very short wire lengths on the sensor and may benefit by splicing-in extra wire. 14. Your new filter is cleanable and reusable. Every 50,000 miles or as needed, clean the filter using K&N cleaning solution and re-oil using K&N filter oil. |
