Powertrain Damper Kit Installation - First Design

(1994 and early 1995 Saturns built before and including VIN SZ1S4030)





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








3. Remove the two transaxle strut bracket fasteners and remove the transaxle strut bracket and discard.

4. Install bench-assembled damper kit by securing it in place with the two transaxle strut bracket fasteners

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





5. Install transaxle strut and fastener to the new modified transaxle strut bracket.

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





6. Install battery tray and loosely install all four battery tray bolts, starting with forward horizontal bolt. Tighten all four bolts after they are all installed.

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

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

7. 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.

8. Install the transaxle strut-to-midrail bolt.

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

9. Make sure the battery cable ends are clean.

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

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





12. 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)

13. Install the positive battery cable first.

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

14. Install the negative battery cable last.

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

15. Install air induction system.

IMPORTANT:
It may be necessary to use a 2 mm (5/64 in.) thick shim between the forward mounting foot on the air cleaner assembly and the midrail.

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