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Home >> Saturn >> 2002 >> L100 >> Repair and Diagnosis >> Steering >> Power Steering System >> Removal & Installation >> Power Steering Gear >> Installation

Power Steering Gear: Installation

  1. One at a time, remove frame bolts and replace cage nuts which are located in the body and use new bolts. Torque retention of old nuts and bolts may not be sufficient.
  2. Install steering gear into vehicle through left wheel opening.
  3. Using powertrain support dolly and Frame Alignment Fixture J43628, raise frame assembly to vehicle and tighten fasteners. Tighten frame assembly-to-body bolts to 90 N.m (66 ft lbs) + 45° to 60°.
    4. Fig 1: Raising Frame Assembly To Vehicle
    G01956237Courtesy of GENERAL MOTORS CORP.
  4. Install new cage nuts for suspension supports. Torque retention of old nuts may not be sufficient.
    5. Fig 2: Installing New Cage Nuts For Suspension Supports
    G01956238Courtesy of GENERAL MOTORS CORP.
  5. Install suspension supports using new bolts and tighten. Tighten suspension support-to-body bolts to 90 N.m (66 ft lbs) + 45° to 60°.
    6. Fig 3: Installing Suspension Supports
    G01956239Courtesy of GENERAL MOTORS CORP.
  6. On vehicles equipped with L61 and manual transaxle, install cradle-to-shifter link pivot pin clip.
    Fig 4: Installing Cradle-To-Shifter Link Pivot Pin Clip
    G01956240Courtesy of GENERAL MOTORS CORP.
    CAUTION: New bolts and nuts must be used as torque retention of old bolts and nuts may not be sufficient.
  7. Using new bolts and nuts, install steering gear to frame. Tighten steering gear-to-frame to 45 N.m (35 ft lbs) + 90° to 105°.
  8. Vehicles equipped with L61 engines and automatic transaxle, install steering gear heat shield. Tighten steering gear heat shield-to-frame to 4 N.m (35 in lbs).
    Fig 5: Installing Steering Gear Heat Shield
    G01956241Courtesy of GENERAL MOTORS CORP.
    NOTE: The tie rod ends must be thoroughly cleaned before installing and tightening.
  9. Install tie rod end into steering knuckle.
  10. Using Steering Linkage Installer J44015 (or equivalent) seat tie rod end into knuckle. Tighten tie rod end linkage installer to 45 N.m (33 ft lbs).
    CAUTION: Use a new nut. Torque retention of old nut may not be sufficient.
    CAUTION: Hold ball stud from turning when installing nut. The boot can become torn and damaged if the ball stud turns.
  11. Remove linkage installer and install new tie rod end nut. Tighten tie rod end-to-steering knuckle nut to 60 N.m (44 ft lbs).
    12. Fig 6: Installing New Tie Rod End Nut
    G01956242Courtesy of GENERAL MOTORS CORP.
  12. Inspect boot for damage and replace if damaged.
    NOTE: Hold ball stud from turning when installing nut. The boot can become torn and damaged if the ball stud turns.
  13. Install stabilizer bar link-to-strut assembly. Tighten stabilizer bar link-to-strut to 65 N.m (48 ft lbs).
  14. Inspect boot for damage and replace if damaged.
  15. Install rear transaxle mount.
    16. Fig 7: Installing Rear Transaxle Mount
    G01956243Courtesy of GENERAL MOTORS CORP.
  16. Install rear transaxle mount to frame bolts. Tighten rear transaxle mount-to-frame bolts to 60 N.m (44 ft lbs).
    17. Fig 8: Installing Rear Transaxle Mount To Frame Bolts
    G01956244Courtesy of GENERAL MOTORS CORP.
  17. Install power steering high pressure and return lines. Tighten power steering lines-to-steering gear to 27 N.m (20 ft lbs).
    18. Fig 9: Installing Power Steering High Pressure And Return Lines
    G01956245Courtesy of GENERAL MOTORS CORP.
  18. Install exhaust manifold pipe on vehicles equipped with L81 engines, and L61 engines with manual transaxles.
  19. Tighten exhaust manifold pipe to exhaust manifold nuts. Tighten exhaust manifold pipe-to-exhaust manifold nuts to 30 N.m (22 ft lbs).
  20. Tighten exhaust manifold pipe to exhaust pipe bolts. Tighten exhaust manifold pipe-to-exhaust pipe bolts to 20 N.m (15 ft lbs).
    21. Fig 10: Tightening Exhaust Manifold Pipe To Exhaust Pipe Bolts
    G01956246Courtesy of GENERAL MOTORS CORP.
  21. Install O2 sensor clamp to underbody attachment nut on vehicles equipped with L61. Tighten O2 sensor clip-to-underbody attachment nut to 4 N.m (35 in lbs).
  22. Connect O2 sensor electrical connector.
    CAUTION: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel bolts to loosen in service.
    23. Fig 11: Connecting O2 Sensor Electrical Connector
    G01956247Courtesy of GENERAL MOTORS CORP.
  23. Install wheel and tire assemblies onto hub.
  24. Install wheel bolts and tighten in a crisscross pattern.
    1. Hand tighten all five wheel bolts.
    2. Use a torque wrench to tighten wheel bolts using a crisscross pattern. Tighten wheel bolts (initial torque) to 63 N.m (46 ft lbs).
    3. Use a torque wrench to final tighten wheel bolts using a crisscross pattern. Tighten wheel bolts (final torque) to 125 N.m (92 ft lbs).
  25. Lower vehicle.
  26. Install the remaining rear transaxle mount to frame bolt. Tighten rear transaxle mount-to-frame bolts to 60 N.m (44 ft lbs).
  27. Install rear transaxle mount through bolt and heat shield (on vehicle with L61 and auto transaxle). Tighten rear transaxle mount through bolt to 90 N.m (66 ft lbs).
    28. Fig 12: Installing Rear Transaxle Mount Through Bolt & Heat Shield
    G01956248Courtesy of GENERAL MOTORS CORP.
  28. Install O2 sensor on exhaust manifold pipe on vehicles equipped with L81 engines. Tighten O2 sensor on exhaust manifold pipe (L81) to 45 N.m (33 ft lbs).
    29. Fig 13: Installing O2 Sensor On Exhaust Manifold Pipe
    G01956249Courtesy of GENERAL MOTORS CORP.
  29. Install exhaust manifold pipe heat shield on vehicles equipped with L81 engines. Tighten exhaust manifold pipe heat shield bolts (L81) to 8 N.m (71 in lbs).
    Fig 14: Installing Exhaust Manifold Pipe Heat Shield
    G01956250Courtesy of GENERAL MOTORS CORP.
    CAUTION: Use Loctite(R) Threadlocker (or equivalent) on threads of pinch bolt.
  30. Install the intermediate shaft onto steering gear and torque pinch bolt. Tighten intermediate shaft pinch bolt to 30 N.m (22 ft lbs).
    31. Fig 15: Installing Intermediate Shaft Onto Steering Gear
    G01956251Courtesy of GENERAL MOTORS CORP.
  31. Bleed power steering system. (Refer to POWER STEERING SYSTEM BLEED PROCEDURE  .)
  32. Set toe. (Refer to ALIGNMENT, WHEELS & TIRES .)
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