Powertrain Damper Kit Installation - Second Design

(1995 Saturns built after and including VIN SZ154031 and 1996-1999 Vehicles)





1. Place the battery tray in a vice and use a rat-tail file to elongate the forward vertical bolt hole. Create an oblong slot that measures 18 mm (23/32 in.). (This is approximately an 8 mm [5/16 in.] increase in the size of the existing bolt hole.)

IMPORTANT:
Do not make the slot any wider than the original width of the hole. Make sure to slot the hole outboard (toward the left front tire if the battery tray was mounted in the vehicle).





2. Remove the forward "tab" and corner of battery tray that was used to retain the S-nut on first design vehicles.

a. Place the battery tray in a vice; mark a drill pilot location 4.76 mm (3/16 in.) in from the upper inside corner of the indentation.

b. Using the marked pilot location, drill a 3/8 in. hole in the battery tray.

NOTICE:
It is essential to maintain a rounded corner in the cutout section of the battery tray. This "roundness" will help relieve stress at the corner and prevent the battery tray from cracking.





c. Using a hacksaw, cut in from the bottom and the side of the battery tray to remove the remainder of the "tab" and corner of battery tray.

3. Remove the transaxle strut. Refer to "Transaxle Strut" in the "Powertrain Mounts" section of the "Chassis Service Manual."








4. Remove the two transaxle strut bracket fasteners and remove the transaxle strut bracket.

5. Install bench-assembled damper kit by securing it in place with the two trans axle strut bracket fasteners

Torque: 54 N.m (40 ft-lbs)

6. Finger start forward vertical battery tray bolt through the damper kit's upper bracket. Tighten loosely to secure bracket location while making sure that the horizontal hole in the upper bracket aligns with its mating hole in the midrail.

7. Raise vehicle on a hoist.

8. Remove left front road wheel.





9. Locate the hole in the midrail that was used on earlier vehicles to secure the battery tray with the forward horizontal battery tray bolt.





10. Locate the forward hole that was used in first design vehicles to secure the battery tray to the midrail. Then using a metric or SAE dimension stepped uni-bit, enlarge the hole to 17 mm or 11/16 in.





IMPORTANT:
This hole will be used to gain access to the inside of the midrail for installation of the M8 x 20 mm bolt.





11. To install M8 x 20 mm bolt, use an extension and a 10 mm socket. Use a magnetic socket or secure the bolt in the socket with RTV.





12. Slide bolt, socket and extension through 17 mm or 11/16 in. hole created in a previous step. Slide the bolt through the opposite hole in the inside of the midrail and through the hole in the damper kit's upper bracket.





13. Install M8 nut onto bolt and tighten.

Torque: 30 N.m (22 ft-lbs)





14. Using 3M(R) WINDO-WELD Primer (Black) (P/N 08643) or equivalent, prime edge of 17 mm or 11/16 in. hole enlarged in outside of midrail.

15. Install road wheel.

Torque: 140 N.m (103 ft-lbs)

16. Lower vehicle from hoist.





17. Install transaxle strut to the new modified transaxle strut bracket.

Torque: 70 N.m (52 ft-lbs)





18. Install battery tray; loosely install all three battery tray bolts, starting with horizontal bolt. Tighten all three bolts after they are all installed.

Torque: Forward Vertical Battery Tray Bolt - 20 N.m (15 ft-lbs)

Torque: Rearward Vertical Battery Tray Bolt - 10 N.m (89 in-lbs)

Torque: Horizontal Battery Tray Bolt - 10 N.m (89 in-lbs)

19. Make sure the damper-to-upper bracket bolt is properly torqued.

Torque: 70 N.m (52 ft-lbs)

IMPORTANT:
The damper-to-upper bracket bolt must be properly torqued.

20. Install transaxle strut-to-midrail.

Torque: 70 N.m (52 ft-lbs)

21. Make sure the battery cable ends are clean.

22. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.

23. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.





24. Install the battery hold-down retainer, locking the battery into the battery tray. Install and tighten the hold-down retainer nut and screw.

Torque: 9 N.m (80 in-lbs)

25. Install the positive battery cable first.

Torque: 17 N.m (151 in-lbs)

26. Install the negative battery cable last.

Torque: 17 N.m (151 in-lbs)

27. Install air induction system.

IMPORTANT:
It may be necessary to use a 2 mm thick shim between the forward mounting foot on the air cleaner assembly and the midrail.

28. Road test vehicle to verify that vibration has been repaired.