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Home >> Saturn >> 2004 >> L300 4D Wagon, 2.2 F >> Repair and Diagnosis >> Steering >> Power Steering System >> Repair Instructions >> Power Steering Gear Replacement >> Installation Procedure

Installation Procedure

IMPORTANT:
  • Do not reuse the frame bolts and cage nuts.
  • Replace the frame bolts and cage nuts one at a time in order to maintain the frame in its current position.
  1. Remove and install new frame bolts and cage nuts. Discard the bolts and nuts.
  2. Install the steering gear into the vehicle through the left wheel opening.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Using the J 43628  , install the frame to the vehicle. Tighten:  Tighten the frame to body bolts and cage nuts to 90 N.m (66 lb ft) plus an additional 45-60 degrees.
    4. Fig 1: Locating Frame-To-Body Bolts
    GM891619Courtesy of GENERAL MOTORS CORP.
    Fig 2: Removing & Installing Front Suspension Support Assembly
    GM891611Courtesy of GENERAL MOTORS CORP.
  4. Install the suspension support using new bolts. Tighten:  Tighten the bolts to 90 N.m (66 lb ft) plus an additional 45-60 degrees.
  5. If equipped with a L61 engine/manual transaxle, install the shifter link pivot pin clip.
  6. Install new steering gear to frame bolts. Tighten:  Tighten the steering gear to frame bolts to 45 N.m (35 lb ft) plus an additional 90-105 degrees.
    7. Fig 3: Locating Shifter Link Pivot Pin Clip
    GM893335Courtesy of GENERAL MOTORS CORP.
    Fig 4: Removing & Installing Power Steering Gear Heat Shield
    GM891603Courtesy of GENERAL MOTORS CORP.
  7. If equipped with a steering gear heat shield, install the heat shield. Refer to Power Steering Gear Heat Shield Replacement .
  8. Install the outer tie rod ends to the steering knuckles. Refer to Rack & Pinion Outer Tie Rod End Replacement .
  9. Connect the stabilizer links to the struts. Refer to Stabilizer Shaft Link Replacement .
  10. Install the rear transaxle mount to frame bolts. Tighten:  Tighten the rear transaxle to frame bolts to 60 N.m (44 lb ft).
    11. Fig 5: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
    Fig 6: Locating Stabilizer Links
    GM891609Courtesy of GENERAL MOTORS CORP.
    Fig 7: Removing & Installing Rear Transaxle Mount
    GM891641Courtesy of GENERAL MOTORS CORP.
    Fig 8: Identifying Power Steering Hoses At Steering Gear - L61
    GM891755Courtesy of GENERAL MOTORS CORP.
  11. Connect the power steering return hose to the steering gear. Tighten:  Tighten the fitting to 27 N.m (20 lb ft).
  12. Connect the power steering pressure hose to the steering gear. Tighten:  Tighten the fitting to 27 N.m (20 lb ft).
    13. Fig 9: Removing & Installing Exhaust Manifold Pipe
    GM891772Courtesy of GENERAL MOTORS CORP.
  13. If equipped with a L81 engine or L61 engine/manual transaxle, install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement in Engine Exhaust.
  14. 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).
    15. Fig 10: Locating O2 Sensor
    GM892079Courtesy of GENERAL MOTORS CORP.
  15. Connect the O2 sensor harness connector.
  16. Install both front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  17. Lower the vehicle.
  18. Install the remaining rear transaxle mount to frame bolt. Tighten:  Tighten the bolt to 60 N.m (44 lb ft).
    19. Fig 11: Removing & Installing Rear Transaxle Mount Through Bolt
    GM891629Courtesy of GENERAL MOTORS CORP.
  19. Install the rear transaxle mount through bolt. Tighten:  Tighten the bolt to 90 N.m (66 lb ft).
  20. If equipped with a L81 engine, install the exhaust manifold pipe heat shield. Refer to Exhaust Pipe Heat Shield Replacement in Engine Exhaust.
    21. Fig 12: Removing & Installing Exhaust Pipe Heat Shield - L81
    GM892049Courtesy of GENERAL MOTORS CORP.
  21. Install the intermediate steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  22. Bleed the power steering system. Refer to Bleeding the Power Steering System .
  23. Set the front toe. Refer to Front Toe Adjustment in Wheel Alignment.
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