Control Valve Body Assembly Installation

1. Lower the valve body into the case and insert the manual link into the manual valve.

Important

The valve body-to-case bolts must be placed in the valve body prior to installation.





2. Install and finger tighten the valve body-to-case dowel bolts first. This procedure must be followed to ensure the valve body is properly aligned to the case. For reference, the bolts are identified as follows:
• The valvebody-to-case dowel bolts
• The upper-to-lower valvebody dowel bolts
• The bolt holding upper and lower valve body
3. Clean and lubricate the fasteners with Saturn Transaxle Fluid. Wipe off excess fluid and install.

Notice

Refer to Fastener Notice in Cautions and Notices.






Notice

Over-torqueing bolts can cause valves to bind.

4. Tighten the valve body-to-case bolts using tightening sequence shown in the illustration.
Tighten

Tighten the valve body assembly bolts to 11 N·m (8 lb ft).





5. Verify the location of the valve body bolts




6. Clean the transaxle case and the valve body cover sealing surfaces with Saturn Choke and Brake Cleaner or equivalent, applied with a clean shop towel.

Important

Install the new gasket during reassembly.

7. Align the valve body cover gasket on the valve body cover and install on the transaxle case.

Important

Clean and lubricate the fasteners with Saturn Transaxle Fluid. Wipe off excess fluid.

8. When installing the valve body cover, ensure to properly tighten the valve body cover bolts using the tightening sequence shown.
Tighten

Tighten the valvebody cover-to-case bolts to 12 N·m (9 lb ft).

9. Verify tightening of the valve body cover bolts to account for gasket relaxation using the tightening sequence shown.
Tighten

Tighten the valve body cover-to-case bolts to 12 N·m (9 lb ft).





10. Install and tighten the master cylinder-to-booster nuts.
Tighten

Tighten the brake master cylinder-to-booster nuts to 27 N·m (20 lb ft).

11. Install and tighten the ABS mid-rail bracket bolt.
Tighten

Tighten the anti-lock brake system (ABS) bracket-to-midrail bolt to 16 N·m (9 lb ft).

12. Connect the transaxle solenoid harness connector.

Notice

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

13. Install the transaxle connector bolt.
Tighten

Tighten the transaxle electrical connector bolt to 3 N·m (27 lb in).





14. Install the battery tray.
15. Install the battery tray bolts.
16. One bolt is located in the fender well.
Tighten

Tighten the battery tray-to-frame rail bolts to 10 N·m (89 lb in).

17. Install the powertrain control module (PCM) and attachment bolts.
Tighten

Tighten the PCM-to-battery tray bolts to 6 N·m (53 lb in).

18. Connect the PCM J2 black 28-way connector and engage the locking device.




19. Ensure the battery tray is clean.
20. Ensure the battery cable ends are clean and free of corrosion. Clean with a wire brush.
21. Ensure the battery is in good physical condition (e.g., no cracks, or obvious damage) and the terminals are clean.
22. Install the battery carefully in the battery tray; ensure the terminals do not short against any metal during installation.
23. Install the battery hold-down retainer, locking the battery into the tray. Install and tighten the hold-down retainer nut and screws.
Tighten

Tighten the battery case bracket stud and nut to 9 N·m (80 lb in).

24. Install the positive battery cable first.
Tighten

Tighten the battery terminal bolts to 17 N·m (13 lb ft).





25. Install the negative battery cable last.
Tighten

Tighten the battery terminal bolts to 17 N·m (13 lb ft).

26. Install the air cleaner and duct assembly. Refer to Air Cleaner Housing and Duct Assembly Replacement .
27. Set the clock.