For 1990-2009 cars

#### Tools Required

• | SA9105E Engine Support Bar Assembly

• | SA91112T Axle Seal Protector

• | SA9132S Lower Control Arm Ball Stud Separator

### Removal Procedure

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

1. Position the vehicle on a hoist.
2. Remove the air induction system. (DOHC shown, SOHC similar.)
3. Disconnect the negative battery cable from the battery.
4. Disconnect the positive battery cable from the battery.
5. Remove the hold-down retaining nut (1) and screws (2), and lift off the battery hold-down retainer (3).
6. Lift the battery out of the vehicle, and place it in a safe location.

Important: One bolt is located in the fender well.

7. Remove the battery tray bolts and the tray.
8. Remove the transaxle strut-to-midrail bracket fastener.
9. Loosen the transaxle strut to transaxle bracket fastener and flip the transaxle strut out of the way.
10. Disconnect all electrical connectors from the transaxle.

• | Back-up light switch

• | Vehicle speed sensor

• | Two ground terminals from top two clutch housing bolts

11. Remove the vent tube retaining clip.
12. Remove the top two clutch housing-to-engine bolts. (Automatic shown, manual similar.)

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

13. Disconnect the spark plug wires from the coil towers.
14. Disconnect the electrical connectors at the electronic ignition module.

Important: Discard the electronic ignition module bolts and replace with new bolts upon installation.

15. Remove the bolts from the electronic ignition module. Remove the electronic ignition module.
16. Remove the shifter cables from the shift arms and from the clutch housing. Use care not to damage the cable boot.

Notice: Removal of the hydraulic damper with a power tool prior to removal of the actuator could result in breaking off the hydraulic line.

Important: Prior to removing the slave cylinder from the clutch housing, make sure that the clutch hydraulic system has sufficient fluid.

17. Rotate the clutch slave cylinder ¼ turn counterclockwise while pushing into the clutch housing. Remove the cylinder from the housing.
18. Remove the two clutch hydraulic dampener to clutch housing fasteners. Wire the actuator cylinder and the dampener to the upper radiator hose.
19. Wire the radiator to the upper radiator support to hold the radiator in place when the cradle is removed.

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

20. Install the engine support bar assembly SA9105E .
21. Place the engine support bar in the vehicle as shown. Place the support bar feet on the outer edge of the shock tower.
22. Connect the bar hooks to the engine support brackets.
23. Position the stabilizer foot on the engine block to the right of the engine oil dipstick.
24. Adjust the hooks and the stabilizer to remove looseness.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

25. Raise the vehicle and drain the transaxle fluid.
26. Remove the front road wheels.
27. Remove the left and the right front inner fender splash shields.
28. Remove the front engine splash shield from the vehicle.
29. Remove the engine strut cradle bracket-to-cradle fasteners.
30. Remove the transaxle mount-to-cradle fastener.
31. Remove the front exhaust pipe-to-manifold fasteners.
32. Remove the front exhaust pipe-to-catalytic converter fasteners.
33. Remove the exhaust pipe support bracket-to-exhaust pipe fasteners.
34. Remove the front exhaust pipe from the vehicle.
35. Remove the steering gear to cradle fasteners. (Power steering gear shown, manual steering gear similar.)
36. Support the steering gear with safety wire.
37. Remove the brake pipe bracket push pin at the rear of the cradle.
38. Remove the engine to transaxle stiffening brace bolts and remove the brace.
39. Remove the dust cover to clutch housing bolts and remove the dust cover.
40. Remove the cotter pin from the lower ball joints and discard. Loosen the nut and back off until the top of the nut is even with the top of the threads.
41. 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.

42. Separate the ball joint from the lower control arm using the SA9132S and remove the nut.
43. Repeat for the opposite side.

Notice: Do not allow screwdriver to contact axle seal or damage to the seal may occur.

44. Separate the left side axle from the transaxle using a large screwdriver or appropriate pry bar.
45. Remove the axle only part way and install SA91112T . Use the seal protector that was previously used or open up the protector at the split line and install around the axle and into the seal. This will protect the seal from being cut by the shaft spline.
46. Separate the right side axle from the intermediate shaft.
47. On DOHC (LL0) vehicles, remove the intake bracket to intake manifold bolt.
48. Remove the intake bracket to intermediate shaft support bolt, and remove the support bracket.
49. Remove the two intermediate shaft to engine block bolts.
50. Carefully slide the intermediate shaft out of the transaxle.
51. Use the powertrain support dolly and two 4 in x 4 in x 36 in pieces of lumber to support the cradle on the dolly.
52. Remove the four cradle-to-body bolts. Carefully lower the cradle from the vehicle with the powertrain support dolly.
53. Support the transaxle securely with a jack.
54. Remove the two bottom clutch housing to engine bolts, and install the guide bolt into the bottom rear clutch housing bolt hole.
55. Separate the transaxle from the engine and lower the transaxle.

### Installation Procedure

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

1. Place the transaxle securely on a jack and position it under the vehicle.
2. Install the axle seal protector into seals on both sides; use the SA91112T .
3. Place the transaxle in any gear.
4. Raise the transaxle into the vehicle to align the input shaft to the center of the clutch. Guide the transaxle into position, rotate back and forth to align input shaft splines to the clutch disc.

Important: Make sure the input shaft splines line up with the clutch disc splines before tightening the clutch housing bolts. Do not use the bolts to pull the transaxle up to the engine.

5. Install the two lower clutch housing to engine bolts.

Tighten
Tighten the clutch housing-to-engine bolts to 140 N·m (103 lb ft).

6. Remove the transaxle jack.
7. Install the axle seal protector tool SA91112T inside the seal.

Notice: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.

8. Install the left-hand side axle into the transaxle.
9. After the splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.
10. Install the axle seal protector tool SA91112T inside the seal. (Left side shown, right side similar.)

Notice: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.

11. Install the intermediate shaft into the transaxle.
12. After the splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.
13. Position the intermediate shaft support and install the two bolts.

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

14. Install the starter bracket to intermediate shaft bolt, if removed.

Tighten
Tighten the intake manifold support bracket-to-intake manifold bolt (LLO) to 30 N·m (22 lb ft).

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

Tighten
Tighten the intake manifold support bracket-to-intake manifold bolt (LLO) to 30 N·m (22 lb ft).

16. Install the intake bracket to intermediate shaft support bolt.

Tighten
Tighten the intake manifold support bracket-to-intermediate shaft support bracket nut (LLO) to 54 N·m (40 lb ft).

17. Install the right axle to intermediate shaft.

Notice: Take care not to damage rubber boot when installing ball joint to knuckle.

18. Clean and lubricate the ball joint threads.

Important: Make sure that the following parts are correctly positioned when raising the cradle into the vehicle.

• | Lower control arm bar studs to knuckle

• | Cooling module support bushings

• | Engine strut cradle bracket

• | Transaxle mount

19. Place the cradle on a lift and raise it to the vehicle and place the lower ball joint into the knuckles when raising the cradle up.

Important: Cradle-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 cradle mounting locations. Mount studs must be guided into holes in cradle as the cradle is installed.

Important: Do not tighten the fasteners at this time.

20. Install the two rear cradle-to-body fasteners.
21. Position the cradle-to-body at the two front cradle-to-body fasteners.
22. Tighten the four cradle-to-body fasteners.

Tighten
Tighten the cradle-to-body bolts to 210 N·m (155 lb ft).

23. Remove the powertrain support dolly.
24. Lower the vehicle and remove the engine support bar SA9105E .
25. Install the transaxle strut, transaxle bracket-to-transaxle bolts, if removed.

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

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

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

27. 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).

28. Remove the cooling module support wire.

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

Tap size 6 x 1.0 mm

Important: Always use new electronic ignition module bolts to insure proper thread sealant.

29. Inspect the new electronic ignition module bolts to make sure they are coated with yellow thread sealant and the mating surfaces are free from grit and dirt.

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.

30. Install the electronic ignition module and bolts. (Automatic shown, manual transaxle similar.)

Tighten
Tighten the electronic ignition module and bolts to 8 N·m (71 lb in).

31. Install the top two clutch housing to engine studs. (Automatic shown, manual transaxle similar.)

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

32. Connect the electrical connectors to the transaxle.

• | Vehicle speed sensor

• | Back-up lamp switch

• | Two ground terminals to the top two clutch housing studs

Tighten
Tighten the ground terminal-to-top clutch housing studs to 25 N·m (18 lb ft).

• | Install the vent hose clip to the housing

33. Connect the shifter cables to the shift arms and the clutch housing. Install the cable retainers.
34. Unwire the clutch hydraulic system from the upper radiator hose. Install the two clutch hydraulic system to clutch housing nuts.

Tighten
Tighten the clutch hydraulic damper bracket-to-case studs at 25 N·m (18 lb ft).

35. Install the actuator into the clutch housing. Push in and rotate ¼ turn clockwise. Install the retaining clip.
36. Check the master cylinder at front of the dash connection to be sure it is locked in place.
37. Install the battery tray.
38. Tighten the battery tray bolts.

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

39. Make sure the 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 the battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
43. Install the battery hold-down retainer (3), locking the battery into the tray. Install and tighten the hold-down retainer nut (1) and screws (2).

Tighten
Tighten the battery hold down-to-battery tray fasteners to 9 N·m (80 lb in).

44. Install the air induction system.
45. Connect the intake air temperature (IAT) sensor connector.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

46. Raise the vehicle on a hoist.
47. Install the transaxle lower mount-to-cradle fastener.

Tighten
Tighten the transaxle mount-to-cradle nut to 50 N·m (37 lb ft).

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

48. Install the two engine strut cradle bracket-to-cradle fasteners.

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

49. Remove the steering gear support wire.
50. Install the steering gear-to-cradle attachment fasteners. (Power steering gear shown, manual similar.)

Tighten
Tighten the steering gear-to-cradle bolt and nut to 50 N·m (37 lb ft).

51. Connect the brake pipe-to-cradle retainer.
52. Insert Graphic SMPMT49304AB. Install the dust cover to clutch housing bolts.

Tighten
Tighten the flywheel housing cover-to-clutch housing bolts to 11 N·m (97 lb in).

53. 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 54 N·m (40 lb ft).

54. Position the exhaust manifold pipe into the vehicle.
55. Install the exhaust manifold pipe-to-exhaust manifold fasteners and tighten.

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

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

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

57. Install the front exhaust pipe clamp support to engine stiffening bracket.

57.1. | Clamp the support to the engine stiffening bracket.

Tighten
Tighten the front exhaust pipe hanger-to-powertrain stiffening brackets bolts to 30 N·m (22 lb ft).

57.2. | Clamp the support to the front exhaust pipe.

Tighten
Tighten the front exhaust pipe hanger strap clamp to 60 N·m (44 lb ft).

58. Install the nut to lower ball joint and tighten.

Tighten
Tighten the front lower control arm ball stud-to-steering knuckle nut to 75 N·m (55 lb ft).

After torquing, 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.

59. Install the right side, left side, and front splash shield to the cradle fasteners.
60. On Coupes, install the right and left lower fascia brace to the cradle J-nuts.

Tighten
Tighten the fascia support-to-cradle fasteners to 10 N·m (89 lb in).

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.

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

Tighten
Tighten the wheel lug nuts, in crisscross pattern, to 140 N·m (103 lb ft).

63. Install the drain plug.

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

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

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

Specification
Saturn Transaxle Fluid: 2.5L (2.6 qt)

65. Install the positive battery cable first.

Tighten
Tighten the battery terminal bolts to 17 N·m (151 lb in).

66. Install the negative battery cable last.

Tighten
Tighten the battery terminal bolts to 17 N·m (151 lb in).

67. Perform the vehicle alignment. Refer to the Alignment procedures in the Chassis Service Manual.