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Home >> Saturn >> 2005 >> Relay AWD >> Repair and Diagnosis >> Body & Frame >> Frames, Subframes & Crossmembers >> Frame And Underbody >> Repair Instructions >> Frame Replacement - Front >> Installation Procedure
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Installation Procedure

  1. If you are replacing the frame, perform the following steps:
    1. Install the lower control arms to the frame. Refer to Lower Control Arm Replacement in Front Suspension.
    2. Install the frame insulators to the frame. Refer to Frame Cushion or Insulator Replacement - Front .
  2. Position the transaxle table with the frame under the vehicle.
    3. Fig 1: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the power steering cooler line does not become trapped by the engine mount during this step.
  3. Lower the vehicle until the frame is close to the vehicle.
  4. Adjust the utility straps as necessary in order to align the powertrain mounts with the frame.
    5. IMPORTANT: Ensure that the alignment pins remain installed during the frame installation.
  5. Inserting two 19 mm (0.75 in) diameter X 203 mm (8.0 in) long guide pins or drill bits into the frame right side alignment holes in order to align the frame.
    6. Fig 2: Identifying Frame Bolts
    GM1548651Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the frame front bolts (2).

    Tighten:  Tighten the bolts to 130 N.m (96 lb ft).

  7. Install the frame straps (5) and bolts (3).

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

  8. Install the frame rear bolts (4).

    Tighten:  Tighten the bolts to 240 N.m (177 lb ft).

  9. Remove the alignment pins from the frame.
  10. Install the transaxle mount nuts. Refer to Automatic Transmission Mount Replacement in Automatic Transaxle - 4T65-E.
  11. Install the engine mount nuts. Refer to Engine Mount Replacement - Right in Engine Mechanical - 3.5L.
  12. Install the wheel speed sensor wiring harnesses to the lower control arms.
  13. Connect the wheel speed sensor electrical connectors.
  14. Install the lower ball joints to the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  15. Install the power steering cooler pipe to the frame. Refer to Power Steering Cooler Pipe/Hose Replacement in Power Steering System.
  16. Install the front engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front End.
  17. Install the power steering gear to the frame. Refer to Power Steering Gear Replacement in Power Steering System.
  18. Install the power steering gear bolts. Refer to Power Steering Gear Replacement in Power Steering System.
  19. Install the power steering gear heat shield. Refer to Power Steering Gear Heat Shield Replacement in Power Steering System.
  20. Install the propeller shaft, if equipped with AWD. Refer to Propeller Shaft Replacement in Propeller Shaft.
  21. Install the catalytic converter pipe, if equipped with AWD. Refer to Catalytic Converter Replacement in Engine Exhaust.
  22. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement (FWD) or Stabilizer Shaft Replacement (AWD) in Front Suspension.
  23. Install both tie rod ends to the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  24. Install the front fender liner. Refer to Wheelhouse Liner Replacement - Front in Exterior Trim.
  25. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  26. Lower the vehicle.
  27. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.5L.
  28. Inspect the front wheel alignment and adjust the toe angle if necessary. Refer to Measuring Wheel Alignment in Wheel Alignment.
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