Installation

1. Clean seal bore in housing.
2. Apply a light bead of Loctite 515 Gasket Eliminator Sealant (P/N 21005993) or equivalent on the diameter of the seal that presses into the bore.
3. Use tool SA9113T to install seal. Place seal on tool and be sure to keep seal lined up with bore during installation. (Automatic shown, manual transaxle similar.)





4. Install flywheel housing dust cover with three bolts.

Torque: 11 Nm (97 inch lbs.)

5. Install engine to transaxle stiffening brace and install brace to engine, and brace to transaxle bolts.

Torque: 54 Nm (40 ft. lbs.)

NOTICE: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.





6. Install axle seal protector tool SA91112T (indicated by the arrow) inside seal. (Left side shown, right side similar.)
7. Install intermediate shaft into transaxle.
8. After splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.





9. Position intermediate shaft support and install two bolts.

Torque: 54 Nm (40 ft. lbs.)

10. 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.)

11. Install intake bracket to intermediate shaft support bolt.

Torque: 54 Nm (40 ft. lbs.)





12. Install right axle to intermediate shaft.

NOTICE: Take care not to damage rubber boot when installing ball joint to knuckle.

13. Clean and lubricate ball joint threads.
14. Position ball joint into steering knuckle.
15. Install nut to lower ball joint and torque.

Torque: 75 Nm (55 ft. lbs.)

If necessary, after torquing, tighten nut additionally to align slot in nut with cotter pin hole in ball joint and install a new cotter pin and bend.
16. Clean and lubricate threads on tie rod end.
17. Position tie rod end into steering knuckle.





18. Install nut to tie rod end and torque.

Torque: 45 Nm (33 ft. lbs.)

If necessary, after torquing, tighten nut additionally to align slot in nut with cotter pin hole in tie rod end, and install a new cotter pin and bend.

NOTICE: Before installing wheel remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel lug nuts to loosen in service.

19. Position wheel onto hub.
20. Install wheel nuts and torque in a crisscross pattern.

Torque: 140 Nm (103 ft. lbs.)

Repeat torquing procedure to make sure torque is correct.

IMPORTANT: Clean and lubricate fastener with Saturn Transaxle Fluid. Wipe off excess fluid and install.





21. Install drain plug.

Torque: 30 Nm (22 ft. lbs.)

22. Fill transaxle to proper level using Saturn Transaxle Fluid.
2.5 L (2.6 US qt.)
23. Check for proper fluid level using "Transaxle Fluid Level Checking Procedure" found in this manual.