FixVault
Home › Saturn › 2001 › SL › Repair and Diagnosis (Single Page) › Engine Mechanical › Mechanical › Engine Mechanical › Removal And Installation › Powertrain Assembly Installation

Powertrain Assembly Installation

TOOLS REQUIRED:  SA9105E 3-Bar Engine Support Fixture

  1. Install clutch disc and pressure plate, if applicable. The yellow dot on the pressure plate should be aligned near the mark on the flywheel. Use service tool SA9145T to align the clutch disk for the manual transaxle input shaft alignment. When installing an automatic transaxle, the yellow dot on the torque converter must be at the 6 o'clock position when the first flexplate to torque converter bolt is tightened.

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

    Torque: Clutch Pressure Plate-to-Flywheel: 25 N.m (19 ft. lbs.) 

    Fig 1: Installing Clutch Disc And Pressure Plate
    G01068784Courtesy of GENERAL MOTORS CORP.
  2. Carefully lift the engine using service tool 3-Bar Engine Support Fixture SA9105E and install it in the frame aligning the transaxle with the engine using two threaded 10 mm x 6 in. long guide pins in the lower attachment holes. Remove the 4 in. x 4 in. x 6 in. wood block if used, from under transaxle.

    Torque: Lower Transaxle Bolts: 130 N.m (96 ft. lbs.) 

    Torque: Upper Transaxle Bolts: 90 N.m (66 ft. lbs.) 

    Torque: Stiffening Bracket-to-Engine/Transaxle: 54 N.m (40 ft. lbs.) 

    Fig 2: Installing Engine In Frame Aligning To Transaxle
    G01068785Courtesy of GENERAL MOTORS CORP.
  3. Install the front engine mount assembly.

    Torque: 

    Front Mount-to-Engine Block: 55 N.m (41 ft. lbs.) 

    NOTE: Install the torque strut bracket-to-frame nuts, but do not tighten until the upper midrail mount is installed.
  4. Install the engine mount torque strut-to-frame bracket, if removed.

    Torque: 

    Engine Strut-to-Frame Bracket and Engine Strut-to-Engine Bracket: 70 N.m (52 ft. lbs.) 

    Fig 3: Installing Torque Strut
    G01068786Courtesy of GENERAL MOTORS CORP.
    NOTE: Installation of the wood block prior to the upper engine torque axis mount installation allows the mount to be easily installed without lifting or jacking the powertrain.
  5. Place a 1 in. x 1 in. x 2 in. long block of wood between the torque strut and frame.
    Fig 4: Place A Block Of Wood Between The Torque Strut And Frame
    G01068787Courtesy of GENERAL MOTORS CORP.
  6. Attach the axle shaft and starter bracket.

    Torque: Axle Shaft Intermediate Bracket-to-Block: 55 N.m (41 ft. lbs.) 

    Torque: Starter Support Bracket-to-Axle Shaft Bracket: 30 N.m (22 ft. lbs.) 

  7. Position the powertrain and frame on the support dolly. Use two 4 in. x 4 in. x 36 in. blocks of wood to support the frame.
    Fig 5: Position The Powertrain And Frame On The Support Dolly
    G01068788Courtesy of GENERAL MOTORS CORP.
  8. Carefully lift the powertrain into the chassis and install the four frame attachment bolts. Use two 9/16 in. x 18 in. long guide pins in forward frame holes next to attachment bolts for aligning frame with chassis.

    Torque: Frame-to-Body: 205 N.m (151 ft. lbs.) 

    Fig 6: Install The Four Frame Attachment Bolts
    G01068789Courtesy of GENERAL MOTORS CORP.
  9. Attach the brake lines to frame and install steering shaft U-joint and bolt.

    Torque: Steering Shaft U-Joint Bolt: 47 N.m (35 ft. lbs.) 

  10. Install the following sensors, if applicable, and position the electrical harness around the engine and attach the following connectors from under the vehicle:
    • Starter solenoid.

      Torque: Starter Solenoid Terminal: 5 N.m (44 in. lbs.) 

    • Generator/starter battery positive terminal.

      Torque: Generator/Starter Battery Positive Terminal: 10 N.m (89 in. lbs.) 

    • Oil pressure sending Unit.

      Torque: Oil Pressure Sending Unit: 45 N.m (33 ft. lbs.) 

    • Knock sensor.

      Torque: Knock Sensor: 25 N.m (19 ft. lbs.) 

    • Crankshaft position sensor.

      Torque: Crankshaft Position Sensor: 9 N.m (80 in. lbs.) 

    • Canister purge solenoid-to-block

      Torque: Canister Purge Solenoid-to-Block: 22 N.m (16 ft. lbs.) 

    • Wiring harness (PCM ground)

      Torque: Wiring Harness (PCM Ground): 10 N.m (89 in. lbs.) 

    • Wiring harness to transaxle case/engine block

      Torque: Wiring Harness-to-Transaxle Case/Engine Block: 25 N.m (18 ft. lbs.) 

    • EVO solenoid (if equipped)
    • Vehicle speed sensor
    • Attach ABS wheel sensors, if equipped.
  11. Install the engine stiffening bracket.

    Torque: Engine Stiffening Bracket: 47 N.m (35 ft. lbs.) 

    NOTE: Do not bend the front exhaust pipe hanger attached to the engine stiffening bracket when servicing the front exhaust pipe and/or catalytic convertor. Bending the bracket may cause premature failure.
  12. Install new exhaust front pipe/catalytic convertor gaskets and front pipe.

    Torque: Exhaust Pipe to Manifold: 31 N.m (23 ft. lbs.) 

    Torque: Exhaust Pipe Bracket to Stiffener Bracket: 47 N.m (35 ft. lbs.) 

    Torque: Exhaust Pipe to Support Bracket: 31 N.m (23 ft. lbs.) 

    Torque: Exhaust Pipe to Catalytic Converter: 48 N.m (35 ft. lbs.) 

  13. Attach heater, lower radiator, and coolant fill hoses and remove radiator safety wire/tie straps.
  14. Install cylinder block coolant drain plug and close radiator drain.

    Torque: Cylinder Block Drain Plugs: 35 N.m (26 ft. lbs.) 

  15. Install knuckle attachment bolts to strut.

    Torque: Knuckle Attachment Bolts-to-Strut: 200 N.m (148 ft. lbs.) 

  16. Install brake calipers.

    Torque: Brake Caliper Bolt: 110 N.m (81 ft. lbs.) 

  17. Install shift cable(s).
  18. Lower vehicle.
    NOTE: Use new shift cable retainers whenever removed.
  19. Install clutch hydraulic slave cylinder, damper and shift cables.
  20. Install automatic transaxle cooler lines.

    Torque: A/C Compressor Brackets-to-Head/Block: 25 N.m (19 ft. lbs.) 

  21. Install A/C compressor assembly.
  22. Install accessory drive belt. Make sure the belt is properly aligned in the pulley grooves.

    Torque: A/C Compressor-to-Front Bracket: 54 N.m (40 ft. lbs.) 

    Torque: A/C Compressor-to-Rear Bracket: 30 N.m (22 ft. lbs.) 

    NOTE: To prevent engine front cover and mount damage, the three front upper mount to engine front cover nuts must be tightened down uniformly.
  23. Install the two engine mounts to midrail bracket nuts first. Next, install the three engine mount to front cover nuts. Remove the wood block from under the torque strut after the upper mount assembly is installed.

    Torque: Engine Mount-to-Front Cover Nuts: 50 N.m (37 ft. lbs.) 

    Torque: Engine Mount-to-Midrail Bracket Nuts: 50 N.m (37 ft. lbs.) 

    Fig 7: Engine Mounts To Midrail Bracket Nuts And Three Engine Mount To Front Cover Nuts
    G01068790Courtesy of GENERAL MOTORS CORP.
  24. Torque the two torque strut bracket-to-frame/nuts.

    Torque: Strut Bracket-to-Frame Nuts: 50 N.m (37 ft. lbs.) 

  25. Install automatic transaxle torque converter to flexplate bolts and dust cover.

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

    Torque: Transaxle Dust Cover: 10 N.m (89 in. lbs.) 

  26. Install the tires and splash shields.

    Torque: Wheel Nuts: 140 N.m (103 ft. lbs.) 

  27. Attach the following electrical and vacuum connectors where applicable:
    • Engine coolant temperature (ECT) sensor
    • Oxygen sensor
    • Idle air control valve (IAC)
    • Injector connectors
    • Ignition coil (two connectors)
    • Throttle position (TP) sensor
    • MAP sensor
    • EGR valve
    • A/C compressor, (if equipped)
    • Brake booster hose at intake manifold or booster
    • Ground connectors (located at transaxle attachment studs and rear side of block above starter).
    1. Attach the automatic transaxle connectors:
      • Neutral safety/selector switch (three connectors)
      • PRNDL switch (two Connectors)
      • Valve body actuator connector
      • Transaxle turbine speed sensor
      • Back-up light switch (manual transaxle)
      • Temperature sensor
      CAUTION: WHENEVER FUEL LINE CONNECTS ARE DISCONNECTED, LUBRICATE STEEL LINE MALE ENDS WITH CLEAN ENGINE OIL. HOLDING STEEL LINE, FIRMLY PRESS ON FEMALE CONNECTOR UNTIL CLICK IS HEARD THEN PULL BACK TO CONFIRM ENGAGEMENT. MAKE SURE THE FUEL LINE CONNECTS ARE FULLY SEATED. PINCHED, KINKED OR DAMAGED FUEL LINES MUST BE REPLACED.
  28. Install the accelerator cable and attach fuel supply and return line quick connector.
  29. Install the upper radiator and deaeration hoses.
    NOTE: Check the upper cooling module grommets for binding or misalignment. The cooling module retaining pins MUST BE centered in the grommets supported by the L bracket(s). If the grommets are pinched, loosen the L bracket(s) and reposition them.
    NOTE: Tighten the L bracket fasteners and check the cooling module for freedom of movement. IT IS EXTREMELY IMPORTANT THAT THE COOLING MODULE BE ABLE TO MOVE FREELY.
    Fig 8: Installing Radiator
    G01068791Courtesy of GENERAL MOTORS CORP.
  30. Install the air induction system, PCV valve and fresh air hoses. Refer to INDUCTION SYSTEM for air induction assembly procedures.
  31. Install the battery cables, positive cable first.

    Torque: Battery Terminal Bolts: 17 N.m (13 ft. lbs.) 

  32. Check oil pan drain plug and fill engine with new oil.

    Torque: Oil Pan Drain Plug: 37 N.m (27 ft. lbs.) 

  33. Reset "Change Oil Soon telltale lamp. Refer to RESETTING CHANGE OIL SOON TELLTALE LAMP .
  34. Fill with coolant. Use only a non-phosphate ethylene glycol-based antifreeze.
    NOTE: Vehicle must be level when filling with coolant.
  35. Prime fuel system:
    1. Cycle ignition on for 5 seconds and then off for 10 seconds.
    2. Repeat  1 twice.
    3. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
    4. If engine does not start, repeat  1- 3 .
  36. Start engine and check for leaks.
  37. Perform a 3 mile road test.
  38. Fill the cooling system surge bottle to the FULL COLD line and check for leaks after the engine has been tested.
About FixVault