Transaxle Installation: Installation

IMPORTANT:  When reinstalling the transaxle, tap out the ignition module mounting holes prior to installing the transaxle.

1. Place transaxle securely on jack and position under vehicle. Install axle seal protector into seals on both sides; use Axle Seal Protector SA91112T.
2. Place transaxle in any gear.
3. Raise transaxle into vehicle to align input shaft to the center of the clutch. Guide transaxle into position, rotate back and forth to align input shaft splines to clutch disc.
   NOTE: Make sure input shaft splines line up with the clutch disc splines before tightening clutch housing bolts. Do not use bolts to pull transaxle up to engine.
4. Install two lower clutch housing to engine bolts.

   Torque Clutch Housing-to-Engine Bolts: 140 N.m (103 ft-lbs) 

   Fig 1: Placing Transaxle On Jack

   Courtesy of GENERAL MOTORS CORP.
5. Remove transaxle jack.
6. Install Axle Seal Protector SA91112T inside seal on transaxle case for left side seal.
   Fig 2: Installing Axle Seal Protector For Left Side Axle Seal

   Courtesy of GENERAL MOTORS CORP.
   NOTE: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.
7. Install left axle into transaxle.
8. After splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.
9. Install Axle Seal Protector SA91112T inside seal on clutch housing for right side seal. (Left side shown, right side similar.)
   NOTE: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.
10. 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.
    Fig 3: Installing Intermediate Shaft

    Courtesy of GENERAL MOTORS CORP.

    Torque Intermediate Shaft Support Bracket-to-Engine Bolts: 54 N.m (40 ft-lbs) 

13. Install starter bracket to intermediate shaft bolt, if removed.

    Torque Intake Manifold Support Bracket-to-Intake Manifold Bolt (LLO): 30 N.m (22 ft-lbs) 

14. On DOHC (LLO) vehicles, position intake manifold support bracket and install intake bracket to intake manifold bolt.

    Torque Intake Manifold Support Bracket-to-Intake Manifold Bolt (LLO): 30 N.m (22 ft-lbs) 

15. Install intake bracket to intermediate shaft support bolt.

    Torque Intake Manifold Support Bracket-to-Intermediate Shaft Support Bracket Nut (LLO): 54 N.m (40 ft-lbs) 

16. Install right axle to intermediate shaft.
    NOTE: Take care not to damage rubber boot when installing ball joint to knuckle.
17. Clean and lubricate ball joint threads.
18. Place frame on lift and raise to vehicle and place lower ball joint into knuckles when raising frame up.
    Fig 4: Raising Frame To Vehicle

    Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  Make sure that the following parts are correctly positioned when raising frame into vehicle.

    • Lower control arm bar studs to knuckle.
    • Cooling module support bushings.
    • Engine strut frame bracket.
    • Transaxle mount.

    IMPORTANT:  Frame-to-body guide pins must be used to maintain proper alignment. Insert using 9/16 in. round steel rod for alignment pins. Alignment holes are at both front frame mounting locations. Mount studs must be guided into holes in frame as frame is installed.

19. Install two rear frame-to-body fasteners.

    IMPORTANT:  Do not tighten fasteners at this time.

    Fig 5: Installing Frame-To-Body Fasteners (1 Of 2)

    Courtesy of GENERAL MOTORS CORP.
    Fig 6: Installing Frame-To-Body Fasteners (2 Of 2)

    Courtesy of GENERAL MOTORS CORP.
20. Position frame-to-body at the two front frame-to-body fasteners.
21. Tighten four frame-to-body fasteners.

    Torque Frame-to-Body Bolts: 210 N.m (155 ft-lbs) 

22. Remove powertrain support dolly.
23. Lower vehicle and remove Engine Support Bar Assembly SA9105E.
24. Install the transaxle strut, transaxle bracket-to-transaxle bolts, if removed.

    Torque Transaxle Strut Bracket-to-Case Bolts: 54 N.m (40 ft-lbs) 

    Fig 7: Installing Transaxle Strut Bracket

    Courtesy of GENERAL MOTORS CORP.
25. Install transaxle strut-to-midrail bracket fastener.

    Torque Transaxle Strut-to-Midrail Bracket Bolt: 50 N.m (37 ft-lbs) 

26. Tighten transaxle strut-to-transaxle bracket fastener, if removed.
    Fig 8: Installing Transaxle Strut-To-Midrail Bracket

    Courtesy of GENERAL MOTORS CORP.

    Torque Transaxle Strut-to-Transaxle Bracket Bolt: 70 N.m (52 ft-lbs) 

27. Remove cooling module support wire.

    IMPORTANT:  Run a tap through ignition module mounting holes in transaxle to remove any thread sealant residue.

    Tap size 6 x 1.0 mm.

28. Inspect electronic ignition module bolts to make sure mating surfaces are free from grit and dirt. If using new bolts, make sure they are coated with yellow thread sealant. Otherwise apply RTV sealant (P/N 21006236) to bolt threads.
    NOTE: Use extreme care when installing the electronic ignition module bolts make sure the bolt head is seated on the electronic ignition module when the torque specification is reached. If the bolt head is not seated on the electronic ignition module, remove the bolt and tap the hole to clean any debris from the threads.
29. Install electronic ignition module and bolts. (Automatic transaxle shown, manual transaxle similar.)

    Torque Electronic Ignition Module and Bolts: 8 N.m (71 in-lbs) 

    Fig 9: Installing Ignition Coil/Module Assembly (Automatic Transaxle Shown; Manual Transaxle Similar)

    Courtesy of GENERAL MOTORS CORP.
30. Install the top two clutch housing to engine studs. (Automatic transaxle shown, manual transaxle similar.)

    Torque Transaxle-to-Engine Studs: 100 N.m (74 ft-lbs) 

    Fig 10: Installing Top Two Clutch Housing-To-Engine Studs (Automatic Transaxle Shown; Manual Transaxle Similar)

    Courtesy of GENERAL MOTORS CORP.
31. Connect electrical connectors to transaxle.
    1. Vehicle speed sensor.
    2. Back-up lamp switch.
    3. Two ground terminals to top two clutch housing studs.

       Torque Ground Terminal-to-Top Clutch Housing Studs: 25 N.m (18 ft-lbs) 

    4. Install vent hose clip to housing if equipped.
    Fig 11: Connecting Electrical Connectors To Transaxle

    Courtesy of GENERAL MOTORS CORP.
32. Connect shifter cables to shift arms and clutch housing. Install cable retainers.
    Fig 12: Connecting Shifter Cables

    Courtesy of GENERAL MOTORS CORP.
33. Unwire clutch hydraulic system from upper radiator hose. Install two clutch hydraulic system to clutch housing nuts.

    Torque Clutch Hydraulic Damper Bracket-to-Case Studs: 25 N.m (18 ft-lbs) 

34. Install actuator into clutch housing. Push in and rotate 1/4 turn clockwise. Install retaining clip.
35. Check master cylinder at front of dash connection to be sure it is locked in place.
    Fig 13: Installing Clutch Hydraulic System To Clutch Housing

    Courtesy of GENERAL MOTORS CORP.
36. Install battery tray and bolts
    1. Bolt in fender well (1).

    Torque Battery Tray-to-Frame Rail Bolts: 10 N.m (89 in-lbs) 

37. Install PCM and PCM attachment bolts.

    Torque PCM-to-Battery Tray Bolts: 6 N.m (53 in-lbs) 

38. Reconnect PCM J2 (black 28-way) harness connector.
    Fig 14: Installing Battery Tray & PCM

    Courtesy of GENERAL MOTORS CORP.
39. Make sure battery tray is clean.
40. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
41. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
42. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
43. Install battery hold-down retainer, locking the battery into the tray. Install and tighten the hold-down retainer nut and screws.
    Fig 15: Installing Battery

    Courtesy of GENERAL MOTORS CORP.

    Torque Battery Hold Down-to-Battery Tray Fasteners: 9 N.m (80 in-lbs) 

44. Install air cleaner housing and duct assembly. Refer to AIR CLEANER HOUSING AND DUCT ASSEMBLY  .
45. Connect the intake air temperature (IAT) sensor connector.
    Fig 16: Installing Air Cleaner Housing & Duct Assembly

    Courtesy of GENERAL MOTORS CORP.
    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.
46. Raise vehicle on hoist.
47. Install transaxle lower mount-to-frame fastener.

    Torque Transaxle Mount-to-Frame Nut: 50 N.m (37 ft-lbs) 

    Fig 17: Installing Transaxle Lower Mount-To-Frame Fastener

    Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  To ensure proper powertrain alignment, make sure that all other mounts have been torqued.

48. Install two engine strut frame bracket-to-frame fasteners.

    Torque Engine Strut Bracket-to-Frame Nuts: 50 N.m (37 ft-lbs) 

    Fig 18: Installing Two Engine Strut Frame Bracket-To-Frame Fasteners

    Courtesy of GENERAL MOTORS CORP.
49. Remove steering gear support wire.
50. Install steering gear-to-frame attachment fasteners. (Power steering gear shown, manual steering gear similar.)

    Torque Steering Gear-to-Frame Bolt & Nut: 50 N.m (37 ft-lbs) 

    Fig 19: Installing Steering Gear-To-Frame Attachment Fasteners (Power Steering Gear Shown; Manual Steering Gear Similar)

    Courtesy of GENERAL MOTORS CORP.
51. Connect brake pipe-to-frame retainer.
    Fig 20: Connecting Brake Pipe-To-Frame Retainer

    Courtesy of GENERAL MOTORS CORP.
52. Install flywheel housing cover and install flywheel housing cover to clutch housing bolts.

    Torque Flywheel Housing Cover-to-Clutch Housing Bolts: 11 N.m (8 ft-lbs) 

    Fig 21: Installing Flywheel Housing Cover

    Courtesy of GENERAL MOTORS CORP.
53. Install engine to transaxle stiffening brace and install brace to engine and transaxle bolts.

    Torque Engine-to-Transaxle Stiffening Brace Bolts: 54 N.m (40 ft-lbs) 

    Fig 22: Installing Engine-To-Transaxle Stiffening Brace

    Courtesy of GENERAL MOTORS CORP.
54. Position exhaust manifold pipe into vehicle.
55. Install exhaust manifold pipe-to-exhaust manifold fasteners and tighten.

    Torque Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 31 N.m (23 ft-lbs) 

    Fig 23: Installing Exhaust Manifold Pipe-To-Exhaust Manifold Fasteners

    Courtesy of GENERAL MOTORS CORP.
56. Install the intermediate exhaust pipe-to-three way catalytic converter flange fasteners.

    Torque Catalytic Converter-to-Intermediate Exhaust Pipe Nuts: 25 N.m (18 ft-lbs) 

    Fig 24: Installing Intermediate Exhaust Pipe-To-Three Way Catalytic Converter Flange Fasteners

    Courtesy of GENERAL MOTORS CORP.
57. Install front exhaust pipe clamp support to engine stiffening bracket.

    Clamp Support to Engine Stiffening Bracket: 

    Torque: 

    Front Exhaust Pipe Hanger-to-Powertrain Stiffening 

    Bracket Bolts: 30 N.m (22 ft-lbs) 

    Clamp Support to Front Exhaust Pipe: 

    Torque Front Exhaust Pipe Hanger Strap Clamp: 60 N.m (44 ft-lbs) 

    Fig 25: Installing Front Exhaust Pipe Clamp Support To Engine Stiffening Bracket

    Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  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.

58. Install nut to lower ball joint, and torque.

    Torque Front Lower Control Arm Ball Stud-to-Steering Knuckle Nut: 75 N.m (55 ft-lbs) 

    Fig 26: Installing Lower Ball Joint Nut (Left Side Shown)

    Courtesy of GENERAL MOTORS CORP.
59. Install right side, left side, and front splash shield to frame fasteners.
    Fig 27: Installing Splash Shields

    Courtesy of GENERAL MOTORS CORP.
60. On Coupes, install right and left lower fascia support to frame J-nuts.

    Torque Fascia Support-to-Frame Fasteners: 10 N.m (89 in-lbs) 

    NOTE: 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.
61. Position wheels onto hubs.
62. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.

    Torque Wheel Lug Nuts (In Crisscross Pattern): 140 N.m (103 ft-lbs) 

63. Install drain plug.

    Torque Transaxle Drain Plug: 30 N.m (22 ft-lbs) 

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

64. Fill transaxle to proper level using Saturn Transaxle Fluid.

    Saturn Transaxle Fluid: 2.5 L (2.6 qt.) 

    CAUTION: THE POSITIVE TERMINAL MUST BE CONNECTED FIRST TO PREVENT ARCING.
65. Install positive battery cable first.

    Torque Battery Terminal Bolts: 17 N.m (13 ft-lbs) 

    IMPORTANT:  Attach positive then negative terminal.

66. Install negative battery cable last.

    Torque Battery Terminal Bolts: 17 N.m (13 ft-lbs) 

67. Perform vehicle alignment. For 2000-01 models, refer to SPECIFICATIONS & PROCEDURES -- SATURN . For 2002 models, refer to SPECIFICATIONS .