Transaxle Installation
1. Flush transaxle oil cooler using SA9165T. (Refer to tool manufacturer's instructions, included with tool.)
2. Tap out ignition module holes with a M6 x 1.0 mm tap.
3. Place transaxle securely on jack and position under vehicle. Install axle seal protector into both sides; use protector SA91112T. Raise transaxle high enough to connect shifter cable.
4. Connect shifter cable to transaxle gear selector lever and insert into converter housing.
5. Raise transaxle into vehicle.
6. Install two lower converter housing-to-engine bolts.
Torque: 130 Nm (96 ft. lbs.)
NOTICE: Use caution not to damage seal while installing axle into transaxle.
7. Insert seal protector (indicated by the arrow) and install left-hand side axle into transaxle.
8. Remove seal protector.
9. Remove transaxle jack.
10. Insert seal protector and 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. On Double Overhead Camshaft (DOHC) (LL0) vehicles, position intake manifold support bracket and install intake bracket to intake manifold bolt.
14. Install intake bracket to intermediate shaft support nut.
Torque: 54 Nm (40 ft. lbs.)
15. Perform cooler line flush using the oil line cooler flusher tool SA9165T. Follow the instructions printed on the tank for the proper procedure. This step must be done when rebuilding or replacing the transaxle in order to remove all debris.
16. Connect transaxle cooler lines to transaxle by pushing lines into cooler fittings until they bottom out.
17. Clean and lubricate ball joint threads.
18. Place cradle on lift and raise to vehicle. 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.
NOTICE: Cradle-to-body guide pins must be used to maintain proper alignment. 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 enough to allow underhood access 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: 70 Nm (52 ft. lbs.)
26. Tighten transaxle strut-to-transaxle bracket fastener (if removed).
Torque: 70 Nm (52 ft. lbs.)
27. Remove cooling module support wire.
NOTICE: Verify threads of bolts, mounting surfaces and threaded holes are clean and free of any residue.
28. Install ignition module and bolts.
NOTICE: Use extreme care when installing the electronic ignition module bolts. Make sure the bolt head is seated on the ignition module when the torque specification is reached. If the bolt head is not seated on the ignition module, remove the bolt and tap the hole to clean any debris from the threads.
Torque: 8 Nm (71 inch lbs.)
NOTICE: Over-torquing of the ignition module will result in cracking the coil housing and damaging the coil.
29. Connect the electrical connector to the ignition module. Push until a click is heard and pull back to confirm a positive engagement.
30. Connect spark plug wires to coil towers. Press the spark plug wire boots firmly into place.
IMPORTANT: Orientation of the wires to the EI module is critical to the operation of both the module and on-board diagnostics. The orientation is 4 1 2 3 respectively from left to right.
31. Install the top two converter housing-to-engine studs.
Torque: 100 Nm (74 ft. lbs.)
32. Connect electrical connectors to transaxle.
a. Actuator circuit connector.
IMPORTANT: Do not over-tighten or damage to the connector plate may occur.
Torque: 2.5 Nm (22 inch lbs.)
b. Vehicle speed and input shaft speed sensors.
c. Transaxle fluid temperature sensor.
d. Selector switch connectors.
e. Two ground terminals to top two converter housing bolts.
Torque: 25 Nm (19 ft. lbs.)
f. Ground wire to neutral (selector) switch.
g. Clip oxygen sensor wire to converter housing.
33. Adjust control cable. Refer to procedure in "In-Vehicle Service" in Automatic Transmission/Transaxle / Service and Repair.
34. Install air induction system.
35. Install battery tray.
36. Torque battery tray bolts.
Torque: 10 Nm (89 inch lbs.)
IMPORTANT: One bolt is located in the fender well.
37. Make sure battery tray is clean.
38. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
39. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
40. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
41. Install the 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.)
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.
42. Raise vehicle on hoist.
43. 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.
44. Install two engine strut cradle bracket-to-cradle fasteners.
Torque: 50 Nm (37 ft. lbs.)
45. Remove steering gear support wire.
Torque: 50 Nm (37 ft. lbs.)
IMPORTANT: For step 45, Left-Hand Drive (LHD) illustration shown first, Right-Hand Drive (RHD) Domestic illustration shown second.
46. Install steering gear-to-cradle attachment fasteners. (Power steering gear shown, manual similar.)
For RHD Domestic vehicles only.
47. Connect brake line-to-cradle retainer.
48. Install torque converter to flex plate bolts.
Torque: 70 Nm (52 ft. lbs.)
49. Install dust cover and install dust cover to converter housing bolts.
Torque: 11 Nm (97 inch lbs.)
50. Install engine to transaxle stiffening brace and install brace-to-engine and transaxle bolts.
Torque: 54 Nm (40 ft. lbs.)
51. Position exhaust manifold pipe into vehicle.
52. Install exhaust manifold pipe-to-exhaust manifold fasteners and tighten.
Torque: 31 Nm (23 ft. lbs.)
53. Install the intermediate exhaust pipe to three-way catalytic converter flange fasteners.
Torque: 25 Nm (18 ft. lbs.)
54. Install front exhaust pipe clamp support to engine stiffening bracket bolts and pipe clamp bolt, if removed.
Clamp Support to Engine Stiffening Bracket:
Torque: 31 Nm (23 ft. lbs.)
Clamp Support to Front Exhaust Pipe:
Torque: 60 Nm (44 ft. lbs.)
55. Install nut to lower ball joint, and torque.
Torque: 75 Nm (55 ft. lbs.)
56. 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.
IMPORTANT: For step 56, LHD illustration shown first, RHD Domestic illustration shown second.
57. Install right side, left side, and front splash shield to cradle fasteners (LHD shown, RHD similar).
58. 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.
59. Position wheels onto hubs.
60. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.
Torque: 140 Nm (103 ft. lbs.)
IMPORTANT: Clean and lubricate fastener with Saturn Transaxle Fluid. Wipe off excess fluid.
61. Install drain plug.
Torque: 30 Nm (22 ft. lbs.)
62. Connect positive battery cable first.
Torque: 17 Nm (151 inch lbs.)
63. Connect negative battery cable last.
Torque: 17 Nm (151 inch lbs.)
IMPORTANT: Fill transaxle slowly or use a vented funnel.
64. Fill transaxle to proper level using Saturn Transaxle Fluid.
7.0 L (7.4 US qt.)
65. Verify fluid level. (Refer to "Transaxle Fluid Level Checking".)
66. Before driving the vehicle after replacing or rebuilding a transaxle, use the service stall system or Scan tool to reset adaptives. Refer to the Learn-In procedure located at beginning of diagnostic charts.
67. Perform vehicle alignment. Refer to "Alignment" procedures in the "Alignment, Wheels and Tires"