SA91112T Differential End Play Gage

SA9132S Lower Control Arm Ball Stud Separator

SA9165T Oil Cooler Line Flusher

Caution: Refer to Vehicle Lifting Caution in the Preface section.




1. Position the vehicle on the hoist. Refer to Lifting and Jacking the Vehicle in General Information

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery terminal.



3. Remove the air cleaner and duct assembly. Refer to Air Cleaner Housing and Duct Assembly Replacement
4. Remove the air box.



5. Remove the transaxle strut-to-midrail bracket fastener.
6. Loosen the transaxle strut-to-transaxle bracket fastener and flip the transaxle strut out of the way.



7. Disconnect the positive battery cable from the battery.
8. Remove the hold-down retaining nut and screw. Lift them off battery hold-down retainer.
9. Lift the battery out of the vehicle, and place the battery in a safe location.



10. Disconnect the powertrain control module (PCM) J2, black 28-way, harness connector by moving the locking device toward the fender.
11. Remove the PCM attachment bolts.
12. Remove and flip the PCM on its side, out of way.
13. Remove the battery tray bolts and the tray.

One bolt is located in the fender well.




14. Disconnect the following items:

•	The transaxle solenoid harness connector

•	The output speed and input speed sensors harness connectors

•	The transaxle fluid temperature sensor harness connectors

•	The transaxle range switch harness connectors

•	The 2 ground terminals from top two converter housing bolts

•	The ground wire from transaxle range switch





Important: Note which spark plug wire is removed from which coil towers. The spark plug wires must be connected to the correct coil towers.

15. Remove the top 2 converter housing-to-engine bolts.



16. Disconnect the spark plug wires from the coil towers.
17. Disconnect the electronic ignition (EI) module harness connector.
18. Remove the bolts from EI module.
19. Remove the EI module.




Important: The 2 cross bars on the engine support have 2 settings, 1 for the SOHC-L24-1 and 1 for the DOHC-LL0-2 engine. The setting locations are marked on the bars as shown.

20. Wire the radiator to the upper radiator support to hold the radiator in place as the frame is removed.



21. Install the SA9105E



22. Place the engine support bar in the vehicle as shown. Place the support bar feet on the outer edge of the shock tower.



23. Connect the bar hooks to the engine support brackets.
24. Position the stabilizer foot on the engine block to the right of the engine oil dipstick.
25. Adjust the hooks and the stabilizer to remove looseness.

Caution: Refer to Vehicle Lifting Caution in the Preface section.




26. Raise the vehicle and drain the transaxle fluid.



27. Remove the front wheels.



28. Remove the right and left splash shields. LHD shown, RHD similar.



29. Remove the front engine splash shield from the vehicle. For coupes, remove the left and right lower fascia braces.



30. Remove the engine strut bracket-to-frame fasteners.



31. Remove the transaxle mount-to-frame fastener. Manual transaxle shown, automatic transaxle similar.



32. Remove the front exhaust pipe-to-manifold fasteners.



33. Remove the front exhaust pipe-to-catalytic converter fasteners.
34. Remove the exhaust pipe support bracket-to-exhaust pipe fasteners.
35. Remove the front exhaust pipe from the vehicle.

Important: LHD illustration shown first, RHD domestic illustration shown second.




36. Remove the steering gear-to-frame fasteners. Power steering gear shown, manual steering gear similar.
37. Support the steering gear with a safety wire.



38. RHD domestic illustration.



39. Remove the brake pipe bracket push pin at the rear of the frame.



40. Remove the engine-to-transaxle stiffening brace bolts and remove the brace.



41. Remove the dust cover to converter housing bolts and remove the dust cover.
42. Remove the torque converter-to-flywheel bolts.



43. Remove the cotter pin from the lower ball joints and discard. Loosen the nut and back the nut off until the top of the nut is even with the top of the threads. Right side shown, left side opposite.
44. Repeat for the opposite side.

Notice: On ABS equipped vehicles, the outer CV joint has a speed sensor ring. Using the incorrect tool or procedure to separate the control arm from the knuckle can damage the ring, resulting in a loss of ABS operation.

Notice: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

Important: It will be necessary to pull down on the lower control arm to remove the castle nut.




45. Separate the ball joint from the lower control arm using tool SA9132S and remove the nut. Left side shown, right side opposite.
46. Repeat for the opposite side.




Notice: Be careful not to damage axle deflector ring.

47. Separate the left side axle from the transaxle using a large screwdriver or appropriate pry bar.
48. Remove the axle only part way and install the axle seal protector SA9112T . Use a seal protector that was previously used or open up protector at the split line and install it around the axle and into the seal. This will protect the seal from being cut by the shaft splines.
49. Separate the right side axle from the intermediate shaft.



50. On DOHC-LL0 engines, remove the intake bracket to intake manifold bolt.
51. Remove the intake manifold support bracket-to-intermediate shaft support bolt.
52. Remove the 2 intermediate shaft support to engine block bolts.
53. Carefully slide the intermediate shaft out of the transaxle.




Important: Prior to reinstalling the cooler lines to the transaxle, the cooler lines must be flushed using SA9165T Oil Cooler Line Flusher. This must be done when rebuilding or replacing the transaxle in order to remove all debris.

Important: To remove the cooler lines from the transaxle squeeze the plastic tabs at the transaxle connector and pull the line out of the connector. The plastic retainer remains on the line.

Important: Prepare for a lot of fluid leakage from the transaxle cooler line fittings once the lines are disconnected.

54. Use the powertrain support dolly and two 4 in x 4 in x 36 in pieces of lumber to support the frame on the dolly.



55. Disconnect the transaxle cooler lines from the transaxle. Use a piece of 3/8 inch rubber hose to connect the 2 cooler lines together. This will prevent oil from dripping and dirt from entering the lines.



56. Remove the 4 frame-to-body bolts. Carefully lower the frame from the vehicle with the powertrain support dolly.



57. Support the transaxle securely with jack.
58. Remove the 2 bottom torque converter housing-to-engine bolts.
59. Separate the transaxle from the engine and lower the transaxle.



60. Lower the transaxle enough to reach the transaxle shifter cable. Disconnect the shifter cable from the transaxle.
61. Remove the shifter cable from the converter housing by squeezing the release tabs.
62. Lower the transaxle from vehicle.

1. Flush the transaxle oil cooler using the Oil Cooler Line Flusher . Refer to tool manufacturer's instructions, included with tool.
2. Tap out the electronic ignition (EI) module holes with a M6 x 1.0 mm tap.
3. Place the transaxle securely on the jack and position it under the vehicle. Install the axle seal protector into both sides; use Axle Seal Protector . Raise the transaxle high enough to connect the shifter cable.





4. Connect the shifter cable to the transaxle gear selector lever and insert it into the converter housing.

Raise the transaxle into the vehicle.

Notice: Refer to Fastener Notice in the Preface section.




5. Install the 2 lower transaxle-to-engine bolts.

Tighten
Tighten the transaxle-to-engine bolts to 130 N·m (96 lb ft).

Notice: Use caution not to damage seal while installing axle into transaxle.




6. Insert the seal protector, indicated by the arrow, and install the left side axle into the transaxle.
7. Remove the seal protector.
8. Remove the transaxle jack.



9. Insert the seal protector and install the intermediate shaft into the transaxle.
10. After the splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.
11. Position the intermediate shaft support and install the 2 bolts.

Tighten
Tighten the intermediate axle shaft support bracket-to-engine block bolts to 54 N·m (40 lb ft).

12. On DOHC-LL0 vehicles, position the intake manifold support bracket and install the intake bracket to the intake manifold bolt.
13. Install the intake bracket to the intermediate shaft support nut.

Tighten
Tighten the intermediate axle shaft support bracket-to-engine block nut to 54 N·m (40 lb ft).

14. Perform a cooler line flush using the SA9165T . Follow the instructions printed on the tank for the proper procedure. This step must be done when rebuilding or replacing the transaxle in order to remove all debris.



15. Connect the transaxle cooler lines to the transaxle by pushing the lines into the cooler fittings until they bottom out.



16. Clean and lubricate the ball joint threads.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Important: Frame-to-body guide pins must be used to maintain proper alignment. Alignment holes are at both front frame mounting locations. Mount studs must be guided into holes in frame as frame is installed.

Important: Position frame-to-body at the 2 front frame-to-body fasteners.

Important: Ensure that the following parts are correctly positioned when raising the frame into vehicle.

•	The lower control arm bar studs-to-knuckle.

•	The cooling module support bushings.

•	The engine strut frame bracket.

•	The transaxle mount.

17. Place the frame on the lift and raise it to the vehicle. Place the lower ball joint into the knuckles when raising the frame up.



18. Install the 2 rear frame-to-body fasteners.
19. Position the frame-to-body at the 2 front frame-to-body fasteners.



20. Tighten the 4 frame-to-body fasteners.

Tighten
Tighten the frame-to-body fasteners to 210 N·m (155 lb ft).

21. Remove the powertrain support dolly.
22. Lower the vehicle enough to allow underhood access and remove the Engine Support Fixture, 3-Bar .



23. Install the transaxle strut, transaxle bracket-to-case bolts, if removed.

Tighten
Tighten the transaxle bracket-to-case bolts to 54 N·m (40 lb ft).




24. Install the transaxle strut-to-midrail bracket fastener.

Tighten
Tighten the transaxle strut-to-midrail bolt to 70 N·m (52 lb ft).

25. Tighten the transaxle strut-to-transaxle bracket fastener, if removed.

Tighten
Tighten the transaxle strut-to-transaxle bracket bolt to 70 N·m (52 lb ft).

26. Remove the cooling module support wire.




Important: Verify threads of bolts, mounting surfaces and threaded holes are clean and free of any residue. If using new bolts, make sure they are coated with yellow thread sealant. Otherwise, apply RTV Sealant P/N 21006236 to bolt threads.

Notice: 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.

Notice: Over-torquing of the ignition module will result in cracking the coil housing and damaging the coil.

27. Install the EI module and bolts.

Tighten
Tighten the ignition module-to-converter housing bolts to 8 N·m (71 lb in).




28. Connect the EI module harness connector. Push until a click is heard and pull back to confirm a positive engagement.

Important: Orientation of the wires to the EI module is critical to the operation of both the module and on-board diagnostics. The orientation is 4, 1, 2, 3 respectively from left to right.

29. Connect the spark plug wires to the coil towers. Press the spark plug wire boots firmly into place.
30. Install the top 2 transaxle-to-engine studs.

Tighten
Tighten the transaxle-to-engine studs to 100 N·m (74 lb ft).

31. Connect the harness connectors to the transaxle.

Notice: Do not over-tighten or damage to the connector plate may occur.

•	The transaxle solenoid harness connector.

Tighten
Tighten the transaxle solenoid harness connector bolt to 2.5 N·m (22 lb in).

•	The output speed and input speed sensors harness connectors.

•	The transaxle fluid temperature sensor harness connector.

•	The trans range switch harness connectors.

•	The 2 ground terminals to the top two converter housing nuts.

Tighten
Tighten the ground terminal-to-converter housing nuts to 25 N·m (19 lb ft).

•	The ground wire to neutral (selector) switch.

•	Clip the O2S-1 wire to the converter housing.




32. Adjust the control cable. Refer to Shift Control Cable Adjustment .
33. Install the air cleaner and duct assembly. Refer to Air Cleaner Housing and Duct Assembly Replacement



34. Install the battery tray.
35. Install the battery tray bolts.
36. One bolt is located in the fender well.

Tighten
Tighten the battery tray-to-frame rail bolts to 10 N·m (89 lb ft).

37. Install the PCM and the attachment bolts.

Important: PCM connector bolt torque is critical.

38. Connect the PCM J1, black 80-way connector and install the attachment bolts.

Tighten
Tighten the PCM J1 connector-to-PCM bolt to 8 N·m (71 lb in).




39. Connect the PCM J2, black 28-way connector and engage the locking device.
40. Ensure the battery tray is clean.
41. Ensure that the battery cable ends are clean and free of corrosion. Clean with a wire brush.
42. Ensure that the battery is in good physical condition, e.g., no cracks, or obvious damage, and that the terminals are clean.
43. Install the battery carefully in the battery tray; ensure that the terminals do not short against any metal during the installation.
44. Install the battery hold-down retainer, locking the battery into the tray. Install and tighten hold-down retainer nut and screws.

Tighten
Tighten the battery case bracket stud and nut to 9 N·m (80 lb in).

Caution: Refer to Vehicle Lifting Caution in the Preface section.




45. Raise the vehicle on the hoist.
46. Install the transaxle lower mount-to-frame fastener. Manual transaxle shown, automatic similar.

Tighten
Tighten the transaxle strut frame bracket-to-frame nut 50 N·m (37 lb ft).

Important: To ensure proper powertrain alignment ensure that all other mounts have been torqued.

47. Install the 2 engine strut frame bracket-to-frame fasteners.

Tighten
Tighten the engine strut bracket-to-frame fastener to 50 N·m (37 lb ft).




48. Remove the steering gear support wire.
49. Install the steering gear-to-frame attachment fasteners. Power steering gear shown, manual similar.

Tighten
Tighten the steering gear-to-frame fasteners to 50 N·m (37 lb ft).

50. LHD ILLUSTRATION



51. RHD DOMESTIC ILLUSTRATION



52. Connect the brake line-to-frame retainer.



53. Install the torque converter to flex plate bolts.

Tighten
Tighten the torque converter-to-flexplate bolts to 70 N·m (52 lb ft).

54. Install the flywheel housing cover and install the flywheel housing cover to converter housing bolts.

Tighten
Tighten the flywheel housing cover-to-converter housing bolts to 11 N·m (8 lb ft).




55. Install the engine to transaxle stiffening brace and install the brace-to-engine and transaxle bolts.

Tighten
Tighten the engine-to-transaxle stiffening brace bolts to 54  N·m (40 lb ft).




56. Position the exhaust manifold pipe into the vehicle.
57. Install the exhaust manifold pipe-to-exhaust manifold fasteners and tighten.

Tighten
Tighten the exhaust pipe front-to-manifold nuts to 31 N·m (23 lb ft).




58. Install the intermediate exhaust pipe-to-three way catalytic converter flange fasteners.

Tighten
Tighten the front exhaust pipe-to-catalytic converter nuts to 25 N·m (18 lb ft).




59. Install the front exhaust pipe clamp support to engine stiffening bracket bolts and the pipe clamp bolt, if removed.

Tighten

•	Tighten the clamp support-to-engine stiffening bracket to 31 N·m (23 lb ft).

•	Tighten the clamp support-to-front exhaust pipe to 60 N·m (44 lb ft).




60. Install the nut to the lower ball joint, and tighten.

Tighten
Tighten the lower ball joint-to-steering knuckle nut to 75 N·m (55 lb ft).

61. After tightening, if necessary, tighten the nut additionally to align the slot in the nut with the cotter pin hole in the ball joint. Install the cotter pin.



62. Install the right side, left side, and front splash shield to frame fasteners. LHD shown, RHD similar.



63. On coupes, install the right and left lower fascia brace to frame J-nuts.

Tighten
Tighten the lower fascia brace-to-frame J-nut to 10 N·m (89 lb ft).

Notice: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel nuts to loosen in service.

64. Position wheels onto hubs.
65. Install the wheel nuts and tighten in a crisscross pattern. Repeat the tightening pattern to ensure the torque is correct.

Tighten
Tighten the wheel lug nuts to 140 N·m 103 lb ft).

Important: Clean and lubricate the fastener with Saturn Transaxle Fluid. Wipe off excess fluid.

66. Install the drain plug.

Tighten
Tighten the transaxle drain plug to 30 N·m (22 lb ft).

67. Connect the positive battery cable first.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

68. Connect the negative battery cable last.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

Important: Fill the transaxle slowly or use a vented funnel.

69. Fill the transaxle to the proper level using Saturn Transaxle Fluid.

Capacity
Transaxle fluid capacities-Overhaul 7.0 L (7.4 qt)

70. Verify the fluid level. Refer to Transmission Fluid Check
71. Before driving the vehicle after replacing or rebuilding a transaxle, use the service stall system or Scan tool to reset adaptives. Refer to the Learn-In procedure.
72. Perform a vehicle alignment. Refer to Alignment in Wheels and Tires.