Operation CHARM: Car repair manuals for everyone.
Home >> Saturn >> 2001 >> LW200 L4-2.2L VIN F >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Replacement - Manual Transaxle

Engine Replacement - Manual Transaxle

ENGINE REPLACEMENT (MANUAL TRANSAXLE)

- TOOLS REQUIRED
- J43628 Frame Alignment Fixture
- J44015 Steering Linkage Installer

REMOVAL
1. Remove steering gear-to-intermediate shaft pinch bolt, access is from inside vehicle at front-of-dash.
2. Remove battery.
3. Disconnect main wire feed to fuse block.
4. Disconnect main ground on left fender well.
5. Remove Intake Air Temperature (IAT) electrical connector.
6. Remove air cleaner lid and inlet duct.
7. Remove air box.
8. Disconnect purge hose from throttle body and route away from engine.
9. Disconnect the following electrical connections:
9.1. Purge solenoid
9.2. Rear H20 sensor
9.3. Main harness connector by master cylinder
9.4. Transaxle back-up switch
10. Remove front-of-dash cover.
11. Remove PCM boot from front-of-dash.
12. Disconnect PCM electrical connectors and secure to engine.
13. Remove fuse block.
14. Disconnect engine harness main connector from bottom of fuse block.
15. Remove battery tray and fuse block tray.
16. Remove cruise control and throttle cables.
17. Disconnect brake assist vacuum line from throttle body and route away from engine.
18. Loosen pinch bolt securing control assembly rod to control shaft lever assembly.

NOTICE: The control shaft lever retaining pin has a spring loaded locking feature securing the pin in place. If this spring is not depressed before attempting to remove pin, damage to pin will result.

19. Remove pin retaining control shaft lever to shift control shaft of transaxle.

20. Remove retaining clips holding control shaft lever assembly to transaxle and frame assembly brackets.
21. Remove control shaft lever assembly by pulling straight up from pivot pins.
22. Drain coolant.
23. Remove heater hoses from front-of-dash.
24. Remove upper and lower radiator hoses from radiator.
25. Relieve fuel pressure.
26. Disconnect fuel lines.
27. Secure radiator to upper radiator support.

CAUTION: MAKE SURE THAT VEHICLE IS PROPERLY AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE SUPPORT TO OPPOSITE END OF VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.

28. Raise vehicle on hoist.
29. Remove both front wheels.
30. Remove right front splash shield.
31. Remove left front wheel liner push pin from frame.
32. Install wood blocks between transaxle case and frame.
33. Install wood blocks between crank pulley and frame.
34. Lower vehicle.
35. Disconnect right engine and left transaxle mounts by removing the mount assembly-to-engine/transaxle bolts, the mount brackets will remain on engine and transaxle.
36. Disconnect rear oxygen sensor harness from frame at the two attachment points.
37. Remove exhaust manifold pipe from catalytic converter forward.
38. Remove A/C line to frame attachment clip at front of frame.

NOTICE: It is not necessary to disconnect A/C lines.

39. Remove A/C compressor from engine and secure to cooling module.
40. Remove tie rod-to-steering knuckle bolts and separate tie rod from steering knuckle assembly. Discard tie rod bolts.
41. Remove stabilizer bar links from strut assembly.

NOTICE: Do not attempt to separate ball studs with a wedge type separator tool because seal may be damaged.

42. Remove lower ball stud bolt and separate ball from steering knuckle assembly.
43. Remove suspension support assemblies.
44. Remove suspension support cage nuts from body. Discard cage nuts.
45. Support powertrain and frame with powertrain lifting table and Frame Alignment Fixture J43628.
46. Remove remaining (4) frame-to-body attachment fasteners.
47. Carefully lower powertrain and frame assembly from vehicle.





48. Remove remain (4) cage nuts and discard.

INSTALLATION
1. Install new cage nuts into body as torque retention of old nuts may not be sufficient.

IMPORTANT: Ensure that service tool J-43628 fully engages into all alignment holes.

2. Carefully raise powertrain into vehicle.

IMPORTANT: Do not tighten fasteners at this time.
3. Install (4) new frame-to-body bolts.
4. Install suspension supports using new bolt and tighten all frame bolts;
Torque:
Suspension Support Bolts: 100 Nm (74 ft. lbs.) + 45°
5. Install ball stud into steering knuckle, use new ball stud nut.
Torque:
Ball Stud-to-Steering Knuckle Nuts: 100 Nm (74 ft. lbs.)
6. Install stabilizer link-to-strut assembly.
Torque:
Stabilizer Link-to-Strut Assembly: 65 Nm (50 ft. lbs.).

NOTICE: Use new tie rod nut, the torque retention of old nut may not be sufficient.

IMPORTANT: The tie rod ends must be thoroughly cleaned before it is installed.

7. Install tie rod into steering knuckle.
8. Using Steering Linkage Installer J44015 (or equivalent) seat tie rod end into knuckle and tighten again.
Torque:
Tie Rod End Linkage Installer: 45 Nm (35 ft. lbs.).
9. Remove linkage installer and install new tie rod nut and tighten.
Torque:
Tie Rod Nut: 60 Nm (45 ft. lbs.).
10. Install exhaust manifold pipe.
11. Install A/C compressor-to-engine mounting bolts.
Torque:
A/C Compressor-to-Block Bolt: 25 Nm (18 ft. lbs.).
12. Install A/C line-to-frame attachment clip at front of frame.
13. Route rear oxygen sensor harness and attach to attachment points.
14. Install right engine mount bolts and install left transaxle mount bolts.
Torque: Engine Mount-to-Engine Mount Bracket Bolts: 55 Nm (41 ft. lbs.)
Transaxle Mount Bolts: 55 Nm (41 ft. lbs.).

CAUTION: MAKE SURE THAT VEHICLE IS PROPERLY AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE SUPPORT TO OPPOSITE END OF VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.

15. Raise vehicle.
16. Remove wood blocks from crank pulley and transaxle case.
17. Install left front wheel liner push pin from frame.
18. Install right front splash shield.
19. Install both front wheels.
20. Lower vehicle.
21. Remove radiator from upper radiator support.
22. Connect fuel lines, use new fuel line retainer clips.
23. Install upper and lower radiator hoses from radiator.
24. Install heater hoses.
25. Connect brake assist vacuum line to brake booster.
26. Install and adjust shift control rod as follows:
26.1. Install shift rod into shift linkage assembly.
26.2. Rotate transaxle shift control shaft clockwise (toward passenger side of vehicle) and depress spring loaded transaxle shift linkage lock pin on transaxle case.
26.3. Pull up shift lever boot.
26.4. Move shift lever to 5th (reverse gate) using a
26.5. 3/8 inch punch to hold in place.
26.6. Tighten pinch bolt.
Torque:
Shift Control Rod Pinch Bolt: 12 Nm (9 ft. lbs.) + 180°
27. Attach cruise control and throttle cables.
28. Install battery tray and fuse block tray.
29. Connect engine harness main connector on bottom of fuse block.
30. Install fuse block.
31. Connect PCM electrical connectors.
32. Install PCM boot under front-of-dash cover.
33. Install front-of-dash cover.
34. Connect the following connections:
- Purge solenoid
- Rear oxygen sensor
- Main harness connector by master cylinder
- Transaxle back-up switch
35. Connect purge hose to throttle body.
36. Install air cleaner box.
37. Install air cleaner lid and inlet duct.
38. Connect Intake Air Temperature (IAT) electrical connection.
39. Connect main ground on left fender well.
40. Connect main wire feed to fuse block.
41. Install battery.
42. Connect steering gear-to-intermediate shaft pinch bolt and tighten.
Torque: Steering Gear-to-Intermediate Shaft Pinch Bolt: 30 Nm (22 ft. lbs.)
43. Refill coolant.
44. Add power steering fluid.
pro multis · About Operation CHARM