Service Procedure

1. Slide EVAP purge solenoid out of bracket near air cleaner assembly and secure out of the way.





2. Remove air cleaner lid.

2.1 Loosen hose clamp on intake flex hose at throttle body.

2.2 Slide intake flex hose off throttle body.

2.3 Disconnect intake air temperature (IAT) sensor connector.

2.4 Release clamps on air cleaner lid.

2.5 Remove air cleaner lid and intake flex hose as an assembly.





3. Remove wiring harness rosebud retainer from air box.

4. Remove air box mounting bolt and remove air box from vehicle.

^ If vehicle is equipped with an automatic transaxle, continue to step 8.
^ If vehicle is equipped with a manual transaxle, continue to step 5.





5. Install engine support fixture (SA915OE) or equivalent on engine.





6. Remove engine mount-to-engine bracket bolts on right engine mount.





7. Remove engine mount-to-frame bolts and remove mount from vehicle.

IMPORTANT:
If unable to read ink stamp codes on engine block, engine must be replaced. (Refer to parts information in this bulletin and "Engine Replacement" procedure in the (L61) Engine Service Manual.)





8. Locate and inspect date code ink stamp on engine block at location 1 shown in illustration.

^ If date code ink stamp is any dates other than 10/29/99, 10/30/99, or the range of dates between and including 11/03/99 - 11/12/99, engine replacement is NOT required.
- If vehicle is equipped with an automatic trans axle, continue to step 24.
- If vehicle is equipped with a manual transaxle, continue to step 21.
^ If date code ink stamp is 10/29/99, continue to step 9.
^ If date code ink stamp is between and including 11/03/99 - 11/12/99, continue to step 10.
^ If date code ink stamp is 10/30/99, engine replacement is required. (Refer to parts information in this bulletin and "Engine Replacement" procedure in the (L61) Engine Service Manual.)

9. Inspect time code ink stamp (for date code 10/29/99 only) on engine block at location 2 shown in illustration.

^ If time code ink stamp is between 08:00 and 23:59, engine replacement is required. (Refer to parts information in this bulletin and "Engine Replacement" procedure in the (L61) Engine Service Manual.)
^ If time code ink stamp is between 00:01 and 07:59, engine replacement is NOT required.
- If vehicle is equipped with an automatic transaxle, continue to step 24.
- If vehicle is equipped with a manual transaxle, continue to step 21.

10. Disconnect negative battery cable.

11. Remove accessory drive belt.

12. Disconnect the two generator electrical connections.

13. Remove generator to engine bolts.





14. It may be helpful to use a YELLOW grease pencil to heavily darken the area on engine block casting boss at location 3 shown in illustration. Then wipe clean.

IMPORTANT:
The letter code stamp on engine block casting boss may be in any orientation.

IMPORTANT:
If unable to read letter code stamp on engine block casting boss, engine must be replaced. (Refer to parts information in this bulletin and "Engine Replacement" procedure in the (L61) Engine Service Manual.)

15. Inspect letter code stamp on engine block casting boss. An inspection mirror may be used to aid in reading the letter code stamp. If letter code stamp is difficult to read, shine a light source across the engine block casting boss from the side. If still difficult to read, repeat steps 14 and 15 as necessary.

^ If letter code stamp is an "A," engine replacement is required. (Refer to parts information in this bulletin and "Engine Replacement" procedure in the (L61) Engine Service Manual.)
^ If letter code stamp is a "B," engine replacement is NOT required. Continue to next step.

16. Position generator and install upper generator to engine bolts finger tight.

17. Install lower generator to engine bolts and tighten all bolts.
Torque: 40 Nm (30 ft-lbs)

18. Connect the two generator electrical connections.

19. Install accessory drive belt.

20. Connect negative battery cable.
Torque: 17 Nm (13 ft-lbs)

^ If vehicle is equipped with an automatic transaxle, continue to step 24. If vehicle is equipped with a manual transaxle, continue to next step.





21. Install engine mount and engine mount-to frame bolts.
Torque: 55 Nm (41 ft-lbs)





22. Install engine mount-to-engine bracket bolts.
Torque: 55 Nm (41 ft-lbs)





23. Remove engine support fixture from engine.





24. Install air box and retaining bolt. Ensure that lower pin fully engages into rubber mounting grommet and that lower duct fits into resonator outlet.

25. Install wiring harness rosebud retainer to air box.





26. Install air cleaner lid and intake flex hose. Ensure that air cleaner lid hinge is fully engaged in air box slots and secure lid clamps.

27. Slide intake flex hose onto throttle body assembly and tighten hose clamp.

28. Connect intake air temperature (JAT) sensor connector.





29. Install EVAP purge solenoid on bracket and slide down to retain.

30. Ensure that a Saturn 2.2 Liter engine identification label is affixed to ignition coil cover on top of engine. If Saturn label is not present, obtain label and affix to ignition coil cover. A pre-shipment of these labels has been automatically shipped to you from SSPO.

31. Affix Campaign Completion Label on a clean and dry surface of radiator core support, in an area clearly visible when hood is raised. (For more information, refer to "Campaign Completion Label" in this bulletin.)