Transaxle Installation

TOOLS REQUIRED
- SA9105E Engine Support Fixture (3-Bar)
- SA91112T Axle Seal Protector
- SA9165T Oil Cooler Line Flusher

1. Flush transaxle oil cooler using Oil Cooler Line Flusher SA9165T. (Refer to tool manufacturer's instructions, included with tool.)
2. Tap out EI module holes with a M6 x 1.0 mm tap.








3. Place transaxle securely on jack and position under vehicle. Install axle seal protector into both sides; use Axle Seal Protector SA91112T. Raise transaxle high enough to connect shifter cable.





4. Connect shifter cable to transaxle gear selector lever and insert into converter housing.
5. Raise transaxle into vehicle.





6. Install two lower transaxle-to-engine bolts.
Torque:
Transaxle-to-Engine Bolts: 130 Nm (96 ft. lbs.)

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





7. Insert seal protector (indicated by the arrow) and install left side axle into transaxle.
8. Remove seal protector.
9. Remove transaxle jack.





10. Insert seal protector and install intermediate shaft into transaxle.
11. After splines clear the seal protector but before snapping the axle into place, remove the seal protector tool.
12. Position intermediate shaft support and install two bolts.
Torque:
Intermediate Axle Shaft Support Bracket-to-Engine Block: 54 Nm (40 ft. lbs.)
13. On DOHC (LL0) vehicles, position intake manifold support bracket and install intake bracket to intake manifold bolt.
14. Install intake bracket to intermediate shaft support nut.
Torque:
Intermediate Axle Shaft Support Bracket-to-Engine Block (LL0): 54 Nm (40 ft. lbs.)
15. Perform cooler line flush using the Oil Cooler Line Flusher Tool 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.





16. Connect transaxle cooler lines to transaxle by pushing lines into cooler fittings until they bottom out.
17. Clean and lubricate ball joint threads.





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

IMPORTANT: Make sure that the following parts are correctly positioned when raising frame into vehicle.
- Lower control arm bar studs-to-knuckle.
- Cooling module support bushings.
- Engine strut frame bracket.
- Transaxle mount.

NOTICE: 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.





19. Install two rear frame-to-body fasteners.

IMPORTANT: Do not tighten fasteners at this time.

20. Position frame-to-body at the two front frame-to-body fasteners.





21. Tighten four frame-to-body fasteners.
Torque:
Frame-to-Body Fasteners: 210 Nm (155 ft. lbs.)
22. Remove powertrain support dolly.
23. Lower vehicle enough to allow underhood access and remove Engine Support Fixture (3-Bar) SA9IOSE.





24. Install the transaxle strut, transaxle bracket-to-case bolts (if removed).
Torque:
Transaxle Bracket-to-Case Bolts: 54 Nm (40 ft. lbs.)





25. Install transaxle strut-to-midrail bracket fastener.
Torque:
Transaxle Strut-to-Midrail Bolt: 70 Nm (52 ft. lbs.)
26. Tighten transaxle strut-to-transaxle bracket fastener (if removed).
Torque:
Transaxle Strut-to-Transaxle Bracket Bolt: 70 Nm (52 ft. lbs.)
27. Remove cooling module support wire.

NOTICE: 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.





28. Install EI module and bolts

NOTICE: Use extreme care when installing the electronic ignition (EI) module bolts. Make sure the bolt head is seated on the EI module when the torque specification is reached. If the bolt head is not seated on the EI module, remove the bolt and tap the hole to clean any debris from the threads.

Torque:
Ignition Module-to-Converter Housing Bolts: 8 Nm (71 inch lbs.)

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





29. Connect 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 l 2 3 respectively from left to right.

30. Connect spark plug wires to coil towers Press the spark plug wire boots firmly into place.





31. Install the top two transaxle-to-engine studs.
Torque:
Transaxle-to-Engine Studs: 100 Nm (74 ft. lbs.)





32. Connect harness connectors to transaxle.

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

32.1 Transaxle solenoid harness connector.
Torque:
Transaxle Solenoid Harness Connector Bolt: 2.5 Nm (22 inch lbs.)
32.2 Output speed and input speed sensors harness connectors.
32.3 Transaxle fluid temperature sensor harness connector.
32.4 Trans range switch harness connectors.
32.5 Two ground terminals to top two converter housing nuts.
Torque:
Ground Terminal-to-Converter Housing Nuts: 25 Nm (19 ft. lbs.)
32.6 Ground wire to neutral (selector) switch.
32.7 Clip 02S-I wire to converter housing.





33. Adjust control cable.
34. Install air cleaner and duct assembly.





35. Install battery tray.
36. Install battery tray bolts.
36.1 One bolt is located in the fender well.
Torque:
Battery Tray-to-Frame Rail Bolts: 10 Nm (89 inch lbs.)
37. Install PCM and attachment bolts.

IMPORTANT: PCM connector bolt torque is critical.

38. Connect PCM J1 (black 80-way) connector and install attachment bolts.
Torque:
PCM J1 Connector-to-PCM Bolt: 8 Nm (71 inch lbs.)





39. Connect PCM J2 (black 28-way) connector and engage locking device.
40. Make sure battery tray is clean.
41. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
42. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
43. Install battery carefully in the battery tray; make sure 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.
Torque:
Battery Case Bracket Stud & Nut: 9 Nm (80 inch lbs.)

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.





45. Raise vehicle on hoist.
46. Install transaxle lower mount-to-frame fastener. (Manual transaxle shown, automatic similar.)
Torque:
Transaxle Strut Frame Bracket-to-Frame Nut: 50 Nm (37 ft. lbs.)

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





47. Install two engine strut frame bracket-to-frame fasteners.
Torque:
Engine Strut Bracket-to-Frame Fastener: 50 Nm (37 ft. lbs.)
48. Remove steering gear support wire.
49. Install steering gear-to-frame attachment fasteners. (Power steering gear shown, manual similar.)
Torque:
Steering Gear-to-Frame Fasteners: 50 Nm (37 ft. lbs.)




LHD ILLUSTRATION





RHD DOMESTIC ILLUSTRATION





50. Connect brake line-to-frame retainer.





51. Install torque converter to flex plate bolts.
Torque:
Torque Converter-to-Flexplate Bolts: 70 Nm (52 ft. lbs.)
52. Install flywheel housing cover and install flywheel housing cover to converter housing bolts.
Torque:
Flywheel Housing Cover-to-Converter Housing Bolts: 11 Nm (8 ft. lbs.)





53. Install engine to transaxle stiffening brace and install brace-to-engine and transaxle bolts.
Torque:
Engine-to-Transaxle Stiffening Brace Bolts: 54 Nm (40 ft. lbs.)





54. Position exhaust manifold pipe into vehicle.
55. Install exhaust manifold pipe-to-exhaust manifold fasteners and tighten.
Torque:
Exhaust Pipe (Front)-to-Manifold Nuts: 31 Nm (23 ft. lbs.)





56. Install the intermediate exhaust pipe-to-three way catalytic converter flange fasteners.
Torque:
Front Exhaust Pipe-to-Catalytic Converter Nuts: 25 Nm (18 ft. lbs.)





57. Install front exhaust pipe clamp support to engine stiffening bracket bolts and pipe clamp bolt, if removed.
Torque:
Clamp Support-to-Engine Stiffening Bracket: 31 Nm (23 ft. lbs.)
Torque:
Clamp Support-to-Front Exhaust Pipe: 60 Nm (44 ft. lbs.)





58. Install nut to lower ball joint, and torque.
Torque:
Lower Ball Joint-to-Steering Knuckle Nut: 75 Nm (55 ft. lbs.)
59. After torquing, if necessary, tighten nut additionally to align slot in the nut with the cotter pin hole in the ball joint. Install the cotter pin.





60. Install right side, left side, and front splash shield to frame fasteners (LHD shown, RHD similar).





61. On coupes, install right and left lower fascia brace to frame J-nuts.
Torque:
Lower Fascia Brace-to-Frame J-nut: 10 Nm (89 inch lbs.)

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

62. Position wheels onto hubs.
63. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to be sure torque is correct.
Torque:
Wheel Lug Nuts: 140 Nm (103 ft. lbs.)

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

64. Install drain plug.
Torque:
Transaxle Drain Plug: 30 Nm (22 ft. lbs.)
65. Connect positive battery cable first.
Torque:
Battery Terminal Bolts: 17 Nm (13 ft. lbs.)
66. Connect negative battery cable last.
Torque:
Battery Terminal Bolts: 17 Nm (13 ft. lbs.)

IMPORTANT: Fill transaxle slowly or use a vented funnel.

67. Fill transaxle to proper level using Saturn Transaxle Fluid.
Transaxle Fluid Capacities (Overhaul): 7.0 Liters (7.4 US quarts)
68. Verify fluid level.
69. Before driving the vehicle after replacing or rebuilding a transaxle, use the service stall system or Scan tool to reset adaptives. Programming and Relearning
70. Perform vehicle alignment.