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Home >> Saturn >> 2003 >> LW200 >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Power Steering Gear Replacement >> Installation Procedure
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Installation Procedure

    IMPORTANT:
    • Do not reuse the frame bolts and cage nuts.
    • Replace the frame bolts and cage nuts one at a time in order to maintain the frame in its current position.
  1. Remove and install new frame bolts and cage nuts. Discard the bolts and nuts.
  2. Install the steering gear into the vehicle through the left wheel opening.
    3. Fig 1: Locating Frame-To-Body Bolts
    GM891619Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTIC in Cautions and Notices.
  3. Using the J 43628  , install the frame to the vehicle.

    Tighten:  Tighten the frame to body bolts and cage nuts to 90 N.m (66 lb ft) plus an additional 45-60 degrees.

    4. Fig 2: Removing & Installing Front Suspension Support Assembly
    GM891611Courtesy of GENERAL MOTORS CORP.
  4. Install the suspension support using new bolts.

    Tighten:  Tighten the bolts to 90 N.m (66 lb ft) plus an additional 45-60 degrees.

    5. Fig 3: Disconnecting Frame-To-Shift Pin Clip - Manual Transmission
    GM893335Courtesy of GENERAL MOTORS CORP.
  5. If equipped with a L61 engine/manual transaxle, install the shiftier link pivot pin clip.
    6. Fig 4: Installing Steering Gear-To-Frame Bolts & Nuts
    GM891603Courtesy of GENERAL MOTORS CORP.
  6. Install new steering gear to frame bolts.

    Tighten:  Tighten the steering gear to frame bolts to 45 N.m (35 lb ft) plus an additional 90-105 degrees.

  7. If equipped with a steering gear heat shield, install the heat shield. Refer to Power Steering Gear Heat Shield Replacement .
    8. Fig 5: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  8. Install the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .
    9. Fig 6: Connecting Stabilizer Bar Link
    GM891609Courtesy of GENERAL MOTORS CORP.
  9. Connect the stabilizer links to the struts. Refer to Stabilizer Shaft Link Replacement .
    10. Fig 7: Removing & Installing Left Transaxle Mount At Engine Compartment Side Rail
    GM891641Courtesy of GENERAL MOTORS CORP.
  10. Install the rear transaxle mount to frame bolts.

    Tighten:  Tighten the rear transaxle to frame bolts to 60 N.m (44 lb ft).

    11. Fig 8: Identifying Power Steering Hoses At Steering Gear - L61
    GM891755Courtesy of GENERAL MOTORS CORP.
  11. Connect the power steering return hose to the steering gear.

    Tighten:  Tighten the fitting to 27 N.m (20 lb ft).

  12. Connect the power steering pressure hose to the steering gear.

    Tighten:  Tighten the fitting to 27 N.m (20 lb ft).

    13. Fig 9: Removing & Installing Exhaust Manifold Pipe
    GM891772Courtesy of GENERAL MOTORS CORP.
  13. If equipped with a L81 engine or L61 engine/manual transaxle, install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (Automatic Transmission - L61) or Exhaust Manifold Pipe Replacement (Manual Transmission - L61) in Engine Exhaust.
    14. Fig 10: Installing O2 Sensor Harness-To-Underbody Clamp Attachment Nut - L61 Engine
    GM892079Courtesy of GENERAL MOTORS CORP.
  14. If equipped with a L61 engine, install the O2 sensor clamp to underbody nut.

    Tighten:  Tighten the nut to 4 N.m (35 lb in).

  15. Connect the O2 sensor harness connector.
  16. Install both front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  17. Lower the vehicle.
    18. Fig 11: Locating Rear Transmission Mount Through-Bolt - Manual Transaxle
    GM891629Courtesy of GENERAL MOTORS CORP.
  18. Install the remaining rear transaxle mount to frame bolt.

    Tighten:  Tighten the bolt to 60 N.m (44 lb ft).

  19. Install the rear transaxle mount through bolt.

    Tighten:  Tighten the bolt to 90 N.m (66 lb ft).

    20. Fig 12: Removing & Installing Exhaust Pipe Heat Shield - L81
    GM892049Courtesy of GENERAL MOTORS CORP.
  20. If equipped with a L81 engine, install the exhaust manifold pipe heat shield. Refer to Exhaust Pipe Heat Shield Replacement in Engine Exhaust.
  21. Install the intermediate steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  22. Bleed the power steering system. Refer to Bleeding the Power Steering System .
  23. Set the front toe. Refer to Front Toe Adjustment in Wheel Alignment.
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