GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Transmission/Transaxle 🢒 Clutch 🢒 Hydraulic Line Replacement

Removal Procedure

    Object Number: 886658 Size: SH
  1. Remove the battery.
    2. 1.1. Disconnect the negative battery cable.
    1.2. Disconnect the positive battery cable.
    1.3. Move the fan control module. Leave the wiring connected, lift the module up and from the bracket, and position out of the way.
    1.4. Remove the battery hold down bracket.
    1.5. Remove the battery.

    Object Number: 886877 Size: SH
  2. Disconnect the battery feed to the underhood fuse block (UHFB).
  3. Disconnect the coolant hose from the UHFB.
  4. Release the retaining tabs on the UHFB cover and remove.
  5. Release the retaining tabs (2) on the UHFB and roll the fuse block back (1) to access the electrical connectors.

    6. Object Number: 886874 Size: SH
  6. Remove the following connectors from the UHFB:
    7. • Engine 68-way (1)
    • Forward Lamp 68-way (2)
    • I/P 68-way (3)
    • Forward Lamp 2-way (White) (4)
    • I/P 2-way (Black) (5)
    • I/P 2-way (Green) (6)
    • I/P 2-way (Brown) (7)
  7. Lift the fuse block off the case.

    8. Object Number: 886875 Size: SH

    Important: There are 2 tabs that hold the hard shell grommets in place at the bottom of the grommet. Disengage the tabs to remove the grommet from the case.

  8. Remove the harnesses from UHFB case.
  9. Remove the UHFB case fastener, and remove the case from the battery tray.

    10. Object Number: 886646 Size: SH
  10. Remove the battery tray fasteners and the battery tray.

    11. Object Number: 895341 Size: SH
  11. Pinch off the clutch master cylinder hose between the brake master cylinder and the clutch master cylinder to prevent excessive brake fluid loss.
  12. Remove the clutch hydraulic line fitting from the transaxle.
  13. Disconnect the clutch hydraulic line assembly from the body retaining clips.

    14. Object Number: 895347 Size: SH
  14. Remove the clutch hydraulic line assembly form the clutch master cylinder, and remove the assembly from the vehicle.

Installation Procedure

    Object Number: 895347 Size: SH
  1. Install the clutch hydraulic line assembly into the vehicle, and attach the line assembly to the clutch master cylinder.
  2. Connect the hydraulic line assembly to the body retaining clips.

    3. Object Number: 895341 Size: SH
  3. Install the clutch hydraulic line assembly to the fitting on the transaxle.

    4. Important: Do not use mineral oil or a paraffin base oil in the hydraulic system. These fluids will damage the rubber parts in the cylinders. Only DOT 3 brake fluid should be used.

  4. Add brake fluid as required and bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding .
  5. Inspect the system for proper operation and fluid leaks. Repair as necessary.

    6. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 886646 Size: SH
  6. Install the battery tray fasteners and the battery tray.

    7. Tighten
    Tighten the battery fasteners to 15 N·m (11 lb ft).


    Object Number: 886877 Size: SH
  7. Install the battery tray fasteners and the battery tray.

    8. Tighten
    Tighten the UHFB case bolt to 9 N·m (80 lb ft).

  8. Install the wire harnesses to the fuse block case. The wire harness grommets have retaining tabs that lock into the case (3) when the harnesses are fully installed.
  9. Snap the fuse block onto the fuse block case hinges (1) .

    10. Object Number: 886874 Size: SH
  10. Install following connectors from UHFB:
    11. • Engine 68-way (1)
    • Forward Lamp 68-way (2)
    • I/P 68-way (3)
    • Forward Lamp 2-way (White) (4)
    • I/P 2-way (Black) (5)
    • I/P 2-way (Green) (6)
    • I/P 2-way (Brown) (7)

    Object Number: 886875 Size: SH
  11. Secure the UHFB to the fuse block case by rotating down and snapping into place.
  12. Install the UHFB cover.
  13. Install the coolant hose into place on the fuse block cover.
  14. Install the battery feed to the UHFB.

    15. Tighten
    Tighten the battery feed cable-to-UHFB to 16 N·m (12 lb ft).


    Object Number: 886658 Size: SH
  15. Install the battery.
    16. 15.1. Install the battery into the battery tray.
    15.2. Install the battery hold down bracket.

    Tighten
    Tighten the battery hold down bracket fasteners to 20 N·m (15 lb ft).

    15.3. Install the fan control module by sliding down onto the battery hold down bracket.

            Important: The positive battery terminal must be connected first to prevent arcing.

    15.4. Install the positive battery cable.

    Tighten
    Tighten the battery cable terminals to 17 N·m (13 lb ft).

    15.5. Install the negative battery cable.

    Tighten
    Tighten the battery cable terminals to 17 N·m (13 lb ft).