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Home >> Saturn >> 2002 >> L100 >> Repair and Diagnosis >> Suspension >> Front Suspension >> Removal & Installation >> Frame Assembly >> Installation

Frame Assembly: Installation

NOTE: Be sure the frame alignment tool fully engages in all gauge holes.
  1. Install new cage nuts into the body as torque retention of old nuts may not be sufficient.
  2. Raise frame assembly to body.
    NOTE: Do not tighten fastener at this time.
  3. Install new frame-to-body bolts.
    4. Fig 1: Installing New Frame-To-Body Bolts
    G01956353Courtesy of GENERAL MOTORS CORP.
  4. Install new cage nuts into the body for the suspension supports, as torque retention of old nuts may not be sufficient.
  5. Install suspension supports using new bolts and tighten all frame bolts using Torque Angle Gauge SA9140E (or equivalent). Tighten suspension support-to-body bolts to 90 N.m (66 ft-lbs) + 45° to 60°.
    Fig 2: Installing Suspension Supports
    G01956354Courtesy of GENERAL MOTORS CORP.
    NOTE: Use a new bolt and nut. Torque retention of old fasteners may not be sufficient.
  6. Install lower control arm ball stud into steering knuckle. Hold the bolt stationary while turning the nut. Tighten lower control arm-to-steering knuckle to 100 N.m (74 ft-lbs).
    7. Fig 3: Installing Lower Control Arm Ball Stud Into Steering Knuckle
    G01956355Courtesy of GENERAL MOTORS CORP.
  7. On vehicles equipped with L61 and manual transaxle, install frame to shifter link pivot pin clip.
    8. Fig 4: Installing Frame To Shifter Link Pivot Pin Clip
    G01956356Courtesy of GENERAL MOTORS CORP.
  8. Install steering gear-to-frame using new bolts and nuts and tighten using Torque Angle Gauge SA9140E (or equivalent). Tighten steering gear-to-frame to 45 N.m (35 ft-lbs) + 90°.
  9. Vehicles equipped with an L61 engine 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
    G01956357Courtesy of GENERAL MOTORS CORP.
    CAUTION: Hold ball stud from turning when tightening nut. The rubber boot can become torn and damaged if the ball stud turns.
  10. Using new nuts, install stabilizer bar link-to-strut assembly. Tighten stabilizer bar link-to-strut to 65 N.m (48 ft-lbs).
    11. Fig 6: Installing Stabilizer Bar Link-To-Strut Assembly
    G01956358Courtesy of GENERAL MOTORS CORP.
  11. Inspect rubber boots for damage and replace if damaged.
  12. Install rear transaxle mount.
  13. Install two rear transaxle mount to frame bolts. Tighten rear transaxle mount-to-frame bolts to 60 N.m (44 ft-lbs).
    14. Fig 7: Installing Two Rear Transaxle Mount To Frame Bolts
    G01956359Courtesy of GENERAL MOTORS CORP.
  14. Install front transaxle mount through bolt. Tighten front transaxle mount through bolt to 55 N.m (41 ft-lbs).
    15. Fig 8: Installing Front Transaxle Mount Through Bolt
    G01956360Courtesy of GENERAL MOTORS CORP.
  15. Install exhaust manifold pipe on L81 engines and on L61 engines with manual transaxles. (L81 shown)
  16. Tighten exhaust manifold pipe to exhaust manifold. Tighten exhaust manifold pipe-to-exhaust manifold nuts to 30 N.m (22 ft-lbs).
  17. Tighten exhaust manifold pipe to exhaust pipe. Tighten exhaust manifold pipe-to-pipe bolts to 20 N.m (15 ft-lbs).
    18. Fig 9: Tightening Exhaust Manifold Pipe To Exhaust Pipe
    G01956361Courtesy of GENERAL MOTORS CORP.
  18. On L61, install O2 sensor clamp to underbody attachment nut. Tighten O2 sensor clip-to-underbody attachment nut to 4 N.m (35 in-lbs).
    19. Fig 10: Installing O2 Sensor Clamp To Underbody Attachment Nut
    G01956362Courtesy of GENERAL MOTORS CORP.
  19. Reattach A/C line clip to front of frame assembly.
    20. Fig 11: Reattaching A/C Line Clip To Front Of Frame Assembly
    G01956363Courtesy of GENERAL MOTORS CORP.
  20. Install right front lower splash shield. Tighten right splash shield-to-body to 5 N.m (44 in-lbs).
  21. Install left front wheel liner push pin to frame.
    Fig 12: Installing Left Front Wheel Liner Push Pin To Frame
    G01956364Courtesy of GENERAL MOTORS CORP.
    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.
  22. Connect O2 sensor electrical connector and reattach harness to frame.
  23. Position wheel onto hub.
    24. Fig 13: Positioning Wheel Onto Hub
    G01956365Courtesy of GENERAL MOTORS CORP.
  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 from hoist.
  26. Install 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 vehicles equipped with 4-cylinder engine and automatic transaxle). Tighten rear transaxle mount through bolt to 90 N.m (66 ft-lbs).
    28. Fig 14: Installing Rear Transaxle Mount Through Bolt & Heat Shield
    G01956366Courtesy of GENERAL MOTORS CORP.
  28. On vehicles equipped with L81 engines, install exhaust manifold pipe heat shield. Tighten exhaust manifold pipe heat shield bolts (L81) to 8 N.m (71 in-lbs).
    29. Fig 15: Installing Exhaust Manifold Pipe Heat Shield
    G01956367Courtesy of GENERAL MOTORS CORP.
  29. Perform vehicle alignment. (Refer to ALIGNMENT, WHEELS & TIRES .)
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