Installation

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

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





2. Install and finger tighten valve body-to-case dowel bolts first. This procedure must be followed to ensure valve body is properly aligned to the case. For reference, the bolts are identified as follows:

(1) Valve body-to-case dowel bolts
(2) Upper-to-lower valve body dowel bolts
(3) Bolt holding upper and lower valve body

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

NOTICE: Over-torqueing bolts can cause valves to bind.





4. Torque valve body-to-case bolts using torque sequence shown in illustration.
- Torque: 11 Nm (8 ft. lbs.)





IMPORTANT: For locations of the valve body bolts, refer to the valve body bolt chart.





VALVE BODY BOLT CHART





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

IMPORTANT: Install new gasket during reassembly.

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

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

7. When installing the valve body cover, make sure to properly torque the valve body cover bolts using the torque sequence shown.
- Torque: 12 Nm (9 ft. lbs.)
8. Verify torque of the valve body cover bolts to account for gasket relaxation using the torque sequence shown.
- Torque: 12 Nm (9 ft. lbs.)





9. Install and torque master cylinder-to-booster nuts.
- Torque: 27 Nm (20 ft. lbs.)
10. Install and torque ABS mid-rail bracket bolt.
- Torque: 12 Nm (9 ft. lbs.)
11. Connect transaxle solenoid harness connector.

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

12. Torque transaxle connector bolt.
- Torque: 3 Nm (27 inch lbs.)





13. Install battery tray.
14. Torque battery tray bolts.
- Torque: 10 Nm (89 inch lbs.)

IMPORTANT: One bolt is located in the fender well.

15. Install PCM and attachment bolts.
- Torque: 6 Nm (53 inch lbs.)

NOTICE: PCM connector bolt torque is critical.

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





17. Make sure battery tray is clean.
18. Make sure battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
19. Make sure battery is in good physical condition (e.g., no cracks, or obvious damage) and terminals are clean.
20. Install battery carefully in battery tray; make sure terminals do not short against any metal during installation.
21. Install battery hold-down retainer, locking battery into tray. Install and tighten the hold-down retainer nut and screws.
- Torque: 9 Nm (80 inch lbs.)
22. Install positive battery cable first.
- Torque: 17 Nm (13 ft. lbs.)
23. Install negative battery cable last.
- Torque: 17 Nm (13 ft. lbs.)





24. Install air cleaner and duct assembly.
25. Set clock.