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Home › Saturn › 2003 › LW200 › Repair and Diagnosis › Body & Frame › Frames, Subframes & Crossmembers › Frame And Underbody › Repair Instructions › Frame Replacement › Installation Procedure

Installation Procedure

  1. Install new frame cage nut and support cage nuts to the vehicle body.
    2. Fig 1: Removing & Installing Lower Control Arm-To-Frame Bolts
    GM891615Courtesy of GENERAL MOTORS CORP.
  2. Install the lower control arms. Refer to Lower Control Arm Replacement in Front Suspension.
    3. Fig 2: Removing & Installing Stabilizer Shaft Assembly
    GM891612Courtesy of GENERAL MOTORS CORP.
  3. Install the stabilizer shaft assembly to the frame. Refer to Stabilizer Shaft Replacement (W/L61) or Stabilizer Shaft Replacement (W/L81) in Front Suspension.
    4. IMPORTANT: The J 43628  must fully engage in all frame gage holes. See Special Tools and Equipment .
  4. Install the frame assembly to the powertrain lifting table and the J 43628  . See Special Tools and Equipment .
  5. Raise the frame assembly to the body.
    6. Fig 3: Locating Frame-To-Body Bolts
    GM891619Courtesy of GENERAL MOTORS CORP.
  6. Loosely install new frame to body bolts.
    7. Fig 4: Removing & Installing Front Suspension Support Assembly
    GM891611Courtesy of GENERAL MOTORS CORP.
  7. Install the suspension supports using new bolts.
    8. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  8. Tighten the suspension support bolts and frame mounting bolts using a SA9140E  . See Special Tools and Equipment .

    Tighten:  Tighten the bolts to 90 N.m (66 lb ft) plus an additional 45-60 degrees.

    9. Fig 5: Connecting Lower Control Arms
    GM891570Courtesy of GENERAL MOTORS CORP.
  9. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.
    10. Fig 6: Disconnecting Frame-To-Shift Pin Clip - Manual Transmission
    GM893335Courtesy of GENERAL MOTORS CORP.
  10. On vehicles equipped with a manual transmission, install the frame to shifter link pivot pin clip.
    11. Fig 7: Installing Steering Gear-To-Frame Bolts & Nuts
    GM891603Courtesy of GENERAL MOTORS CORP.
  11. Install the steering gear to the frame using new frame to steering gear bolts.

    Tighten:  Tighten the bolts to 45 N.m (33 lb ft) plus 90 degrees.

  12. If equipped with a L61 engine, install the steering gear heat shield. Refer to Power Steering Gear Heat Shield Replacement in Power Steering System.
    13. Fig 8: Connecting Stabilizer Bar Link
    GM891609Courtesy of GENERAL MOTORS CORP.
  13. Using new nuts, connect the stabilizer bar link to the struts. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    14. Fig 9: Removing & Installing Remaining Rear Transaxle Mount-To-Frame Bolts
    GM891601Courtesy of GENERAL MOTORS CORP.
  14. Place the rear transaxle mount to the frame and install 2 mount to frame bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

    15. Fig 10: Removing/Installing Front Transaxle Mount Through Bolt
    GM891595Courtesy of GENERAL MOTORS CORP.
  15. Install the front transaxle mount through bolt.

    Tighten:  Tighten the bolt to 55 N.m (41 lb ft).

  16. Connect the exhaust manifold pipe to the manifold on the L61 engine or manifolds on the L81 engine. Refer to Exhaust Manifold Pipe Replacement (Automatic Transmission - L61) or Exhaust Manifold Pipe Replacement (Manual Transmission - L61) in Engine Exhaust.
    17. Fig 11: Installing O2 Sensor Harness-To-Underbody Clamp Attachment Nut - L61 Engine
    GM892079Courtesy of GENERAL MOTORS CORP.
  17. If equipped with a L61 engine, install the O2 sensor clamp to underbody nut.

    Tighten:  Tighten the nut to 4 N.m (35 lb in).

    18. Fig 12: Connecting A/C Pipe-To-Frame Clip
    GM892718Courtesy of GENERAL MOTORS CORP.
  18. Secure the A/C pipe clip to the front frame assembly.
    19. Fig 13: Removing/Installing Right Front Lower Splash Shield
    GM894225Courtesy of GENERAL MOTORS CORP.
  19. Install the right front lower splash shield.

    Tighten:  Tighten the splash shield to body bolts to 5 N.m (45 lb in).

  20. Install the left front wheel liner push pin to the frame assembly.
    21. Fig 14: Attaching Rear O2 Sensor Harness To Frame
    GM892567Courtesy of GENERAL MOTORS CORP.
  21. Attach the O2 sensor harness to the frame assembly.
  22. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  23. Lower the vehicle.
    24. Fig 15: Removing & Installing Transaxle Mount Bolts
    GM891585Courtesy of GENERAL MOTORS CORP.
  24. Install the remaining rear mount to frame bolt.

    Tighten:  Tighten the bolt to 60 N.m (44 lb ft).

  25. Install the rear transaxle mount through bolt.

    Tighten:  Tighten the bolt to 90 N.m (66 lb ft).

    26. Fig 16: Removing & Installing Rear Exhaust Manifold Heat Shield
    GM892053Courtesy of GENERAL MOTORS CORP.
  26. If equipped with a L81 engine, install the rear exhaust manifold pipe heat shield. Refer to Exhaust Pipe Heat Shield Replacement in Engine Exhaust.
  27. Align the front end. Refer to Measuring Wheel Alignment in Wheel Alignment.
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