Transaxle Installation
IMPORTANT: When reinstalling the transaxle, tap out the ignition module mounting holes prior to installing the transaxle.
1. Place transaxle securely on jack and position under vehicle. Install axle seal protector into seals on both sides; use protector SA91112T.
2. Place transaxle in any gear.
3. Raise transaxle into vehicle to align input shaft to the center of the clutch. Guide transaxle into position, rotate back and forth to align input shaft splines to clutch disc.
NOTICE: Make sure input shaft splines line up with the clutch disc splines before tightening clutch housing bolts. Do not use bolts to pull transaxle up to engine.
4. Install two lower clutch housing to engine bolts.
Torque: 140 Nm (103 ft. lbs.)
5. Remove transaxle jack.
6. Install axle seal protector tool SA91112T inside seal.
NOTICE: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.
7. Install left-hand side axle into transaxle.
8. After splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.
9. Install axle seal protector tool SA91112T inside seal. (Left side shown, right side similar.)
NOTICE: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.
10. Install intermediate shaft into transaxle.
11. After splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.
12. Position intermediate shaft support and install two bolts.
Torque: 54 Nm (40 ft. lbs.)
13. Install starter bracket to intermediate shaft bolt, if removed.
Torque: 30 Nm (22 ft. lbs.)
14. On Double Overhead Cam (DOHC) (LL0) vehicles, position intake manifold support bracket and install intake bracket to intake manifold bolt.
Torque: 30 Nm (22 ft. lbs.)
15. Install intake bracket to intermediate shaft support bolt.
Torque: 54 Nm (40 ft. lbs.)
16. Install right axle to intermediate shaft.
NOTICE: Take care not to damage rubber boot when installing ball joint to knuckle.
17. Clean and lubricate ball joint threads.
18. Place cradle on lift and raise to vehicle and place lower ball joint into knuckles when raising cradle up.
IMPORTANT: Make sure that the following parts are correctly positioned when raising cradle into vehicle:
a. Lower control arm bar studs to knuckle.
b. Cooling module support bushings.
c. Engine strut cradle bracket.
d. Transaxle mount.
Cradle-to-body guide pins must be used to maintain proper alignment. Insert using 9/16 inch round steel rod for alignment pins. Alignment holes are at both front cradle mounting locations. Mount studs must be guided into holes in cradle as cradle is installed.
19. Install two rear cradle-to-body fasteners.
IMPORTANT: Do not tighten fasteners at this time.
20. Position cradle-to-body at the two front cradle-to-body fasteners.
21. Tighten four cradle-to-body fasteners.
Torque: 210 Nm (155 ft. lbs.)
22. Remove powertrain support dolly.
23. Lower vehicle and remove engine support bar SA9105E.
24. Install the transaxle strut, transaxle bracket-to-transaxle bolts, if removed.
Torque: 54 Nm (40 ft. lbs.)
25. Install transaxle strut-to-midrail bracket fastener.
Torque: 50 Nm (37 ft. lbs.)
26. Tighten transaxle strut-to-transaxle bracket fastener, if removed.
Torque: 70 Nm (52 ft. lbs.)
27. Remove cooling module support wire.
IMPORTANT: Run a tap through ignition module mounting holes in transaxle to remove any thread sealant residue. Tap size: 6 x 1.0 mm.
28. Inspect new electronic ignition module bolts to make sure they are coated with yellow thread sealant and the mating surfaces are free from grit and dirt.
IMPORTANT: Always use new electronic ignition module bolts to insure proper thread sealant.
NOTICE: Use extreme care when installing the electronic ignition module bolts. Make sure the bolt head is seated on the electronic ignition module when the torque specification is reached. If the bolt head is not seated on the electronic ignition module, remove the bolt and tap the hole to clean any debris from the threads.
29. Install electronic ignition module and bolts. (Automatic shown, manual transaxle similar.)
Torque: 8 Nm (71 inch lbs.)
30. Install the top two clutch housing-to-engine studs. (Automatic shown, manual transaxle similar.)
Torque: 100 Nm (74 ft. lbs.)
31. Connect electrical connectors to transaxle.
a. Vehicle speed sensor.
b. Back-up light switch.
c. Two ground terminals to top two clutch housing studs.
Torque: 25 Nm (18 ft. lbs.)
d. Install vent hose clip to housing.
32. Connect shifter cables to shift arms and clutch housing. Install cable retainers.
33. Unwire clutch hydraulic system from upper radiator hose. Install two clutch hydraulic system to clutch housing nuts.
Torque: 25 Nm (18 ft. lbs.)
34. Install actuator into clutch housing. Push in and rotate 1/4 turn clockwise. Install retaining clip.
35. Check master cylinder at front of dash connection to be sure it is locked in place.
36. Install battery tray.
37. Torque battery tray bolts.
Torque: 10 Nm (89 inch lbs.)
38. Make sure battery tray is clean.
39. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
40. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
41. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
42. Install battery hold-down retainer (3), locking the battery into the tray. Install and tighten the hold-down retainer nut (1) and screws (2).
Torque: 9 Nm (80 inch lbs.)
43. Install air induction system.
44. Connect the Intake Air Temperature (IAT) sensor connector.
CAUTION: Make sure vehicle is properly supported and squarely positioned on hoist. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.
45. Raise vehicle on hoist.
46. Install transaxle lower mount-to-cradle fastener.
Torque: 50 Nm (37 ft. lbs.)
IMPORTANT: To insure proper powertrain alignment, make sure that all other mounts have been torqued.
47. Install two engine strut cradle bracket-to-cradle fasteners.
Torque: 50 Nm (37 ft. lbs.)
48. Remove steering gear support wire.
49. Install steering gear-to-cradle attachment fasteners. (Power steering gear shown, manual similar.)
Torque: 50 Nm (37 ft. lbs.)
50. Connect brake pipe-to-cradle retainer.
51. Install dust cover and install dust cover to clutch housing bolts.
Torque: 11 Nm (97 inch lbs.)
52. Install engine to transaxle stiffening brace and install brace to engine and transaxle bolts.
Torque: 54 Nm (40 ft. lbs.)
53. Position exhaust manifold pipe into vehicle.
54. Install exhaust manifold pipe-to-exhaust manifold fasteners and tighten.
Torque: 31 Nm (23 ft. lbs.)
55. Install the intermediate exhaust pipe-to-three way catalytic converter flange fasteners.
Torque: 25 Nm (18 ft. lbs.)
56. Install front exhaust pipe clamp support to engine stiffening bracket.
Clamp Support to Engine Stiffening Bracket:
Torque: 30 Nm (22 ft. lbs.)
Clamp Support to Front Exhaust Pipe:
Torque: 60 Nm (44 ft. lbs.)
57. Install nut to lower ball joint, and torque.
Torque: 75 Nm (55 ft. lbs.)
After torquing, if necessary, tighten nut additionally to align slot in the nut with the cotter pin hole in the ball joint. Install the cotter pin.
58. Install right side, left side, and front splash shield to cradle fasteners.
59. On Coupes, install right and left lower fascia brace to cradle J-nuts.
Torque: 10 Nm (89 inch lbs.)
NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel lug nuts to loosen in service.
60. Position wheels onto hubs.
61. Install wheel nuts and tighten in a crisscross pattern.
Torque: 140 Nm (103 ft. lbs.)
Repeat tightening pattern to be sure torque is correct.
62. Install drain plug.
Torque: 30 Nm (22 ft. lbs.) (with rubber seal)
IMPORTANT: Clean and lubricate fastener with Saturn Transaxle Fluid. Wipe off excess fluid and install.
63. Fill transaxle to proper level using Saturn Transaxle Fluid.
2.5 L (2.6 US qt.)
64. Install the positive battery cable first.
Torque: 17 Nm (151 inch lbs.)
CAUTION: The positive terminal must be connected first to prevent arcing.
65. Install the negative battery cable last.
Torque: 17 Nm (151 inch lbs.)
66. Perform vehicle alignment. Refer to "Alignment" procedures in the "Chassis Service Manual."