Valvebody Cover Replacement
Valvebody Cover Replacement
Removal Procedure
1. Remove the air cleaner and duct assembly. Refer to Air Cleaner Housing and Duct Assembly Replacement in HVAC.
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited OnStar functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar module). Do not disconnect the main vehicle battery or remove the OnStar fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar module in any way while the ignition is On or with RAP activated may cause activation of the OnStar Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.
2. Disconnect the negative battery cable from the battery.
Disconnect the positive battery cable from the battery.
3. Remove the hold-down retaining nut and screws, and lift the nut and screws off the battery hold-down retainer.
4. Lift the battery out of the vehicle, and place the battery in a safe location.
5. Disconnect the powertrain control module (PCM) J2 (black 28-way) harness connector by moving the locking device toward fender.
6. Remove the PCM attachment bolts.
7. Remove and flip the PCM on its side, out of the way.
8. Remove the battery tray bolts and tray.
9. One bolt is located in the fender well.
10. Back out the transaxle connector bolt and disconnect the transaxle connector.
Notice: ABS equipped vehicles require the master cylinder to be moved off booster studs and the ABS mid-rail bracket bolt removed to allow the system to be lifted slightly for removal of the valvebody cover. Use care not to bend or kink brake lines. After removing the valvebody cover place the master cylinder back on the booster studs.
11. For anti-lock brake system (ABS) equipped vehicles, remove the master cylinder-to-booster nuts and the ABS mid-rail bracket bolt.
12. Remove the valvebody cover.
Installation Procedure
1. Clean the transaxle case and the valvebody cover sealing surfaces with Saturn Choke and Brake Cleaner or equivalent, applied with a clean shop towel.
Important: Install the new gasket during reassembly.
2. Align the valvebody cover gasket on the valvebody cover and install on the transaxle case.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Important: Clean and lubricate the fasteners with Saturn Transaxle Fluid. Wipe off excess fluid.
3. When installing the valvebody cover, ensure to properly torque the valvebody cover bolts using the torque sequence shown.
Tighten
Tighten the valvebody cover-to-case bolts to 12 Nm (9 lb ft).
4. Verify the torque of the valvebody cover bolts to account for gasket relaxation using the torque sequence shown.
Tighten
Tighten the valvebody cover-to-case bolts to 12 Nm (9 lb ft).
5. Install and torque the master cylinder-to-booster nuts.
Tighten
Tighten the brake master cylinder-to-booster nuts to 27 Nm (20 lb ft).
6. Install and torque the ABS mid-rail bracket bolt.
Tighten
Tighten the ABS bracket-to-midrail bolt to 16 Nm (9 lb ft).
7. Connect the transaxle solenoid harness connector.
Notice: Do not over-tighten or damage to the connector plate may occur.
8. Tighten the transaxle connector bolt.
Tighten
Tighten the transaxle electrical connector bolt to 3 Nm (27 lb in).
9. Install the battery tray.
10. Install the battery tray bolts. One bolt is located in the fender well.
Tighten
Tighten the battery tray-to-frame rail bolt to 10 Nm (89 lb ft).
11. Install the PCM and the attachment bolts.
Tighten
Tighten the PCM-to-battery tray bolts to 6 Nm (53 lb ft).
12. Connect the PCM J2 black 28-way connector and engage the locking device.
13. Ensure the battery tray is clean.
14. Ensure the battery cable ends are clean and free of corrosion. Clean with a wire brush.
15. Ensure the battery is in good physical condition (e.g., no cracks, or obvious damage) and the terminals are clean.
16. Install the battery carefully in the battery tray; ensure the terminals do not short against any metal during installation.
17. Install the battery hold-down retainer, locking the battery into the tray. Install and tighten the hold-down retainer nut and screws.
Tighten
Tighten the battery case bracket stud and nut to 9 Nm (80 lb ft).
18. Install the positive battery cable first.
Tighten
Tighten the battery terminal bolts to 17 Nm (13 lb ft).
19. Install the negative battery cable last.
Tighten
Tighten the battery terminal bolts to 17 Nm (13 lb ft).
20. Install the air cleaner and duct assembly.
21. Set the clock.