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1. Remove the instrument panel cluster. Refer to Instrument Cluster Replacement . 2. Remove the cluster lamp. Installation Procedure 1. Install the cluster lamp. 2. Install the instrument panel cluster. Refer to Instrument Cluster Replacement
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1. Pull out on the accessory trim plate in order to release the retaining fasteners. 2. Disconnect the accessory trim plate electrical connector(s). 3. Remove the screw retaining the cluster trim plate to the center trim panel. 4. Lift up on the cluster trim plate to release the retaining fasteners. 5. Remove the cluster trim plate. 6. Remove the cluster screws 7. Pull the cluster out and disconnect the electrical connector. 8. Remove the cluster from the vehicle. Installation Procedure 1. Position the cluster in the vehicle and connect the cluster electrical connector. Notice: Refer to Fastener Notice in the Preface section. 2. Install the cluster screws Tighten Tighten the cluster screws to 2.5 N·m (22 lb in). 3. Align the cluster trim plate retaining fasteners with the center trim panel. 4. Push on the outer edge of the cluster trim plate in order to secure the retaining fasteners. 5. Install the screw retaining the cluster trim plate to the center trim panel. Tighten Tighten the cluster trim plate screw to 2.5 N·m (22 lb in). 6. Connect the accessory trim plate electrical connector(s). 7. Align the retaining fasteners with the I/P. 8. Push on the outer edge of the accessory trim plate in order to secure the retaining fasteners.
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1. Remove the lower control arm. 2. Place the control arm in a vise or suitable holding device. 3. Remove the ball joint rivets using the following procedure. 3.1. Drill through the rivets using a 8 mm (5/16 in.) drill bit. 3.2. Enlarge the hole using a 12 mm (31/64 in.) drill bit. 3.3. Remove any remaining burs from the control arm. 4. Remove the ball joint from the control arm. Note the position of the ball joint for reassembly. Installation Procedure Important: The control arm must be clean and free of debris. 1. Install the ball joint to the control arm as previously noted. Notice: Refer to Fastener Notice in Cautions and Notices. Important: Only use hardware provided with the new ball joint. The bolts must be installed with the bolt head on top of the ball joint. 2. Install the ball joint to control arm bolts. Tighten the bolts and nuts to 68 Nm (50 ft. lbs.) . 3. Install the lower control arm.
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Removal Procedure 1. Lower the window to the full down position. 2. Remove the door trim panel. Refer to Trim Panel Replacement – Side Front Door (See: Body and Frame\Doors, Hood and Trunk\Front Door Panel\Service and Repair\Front Door Panel Replacement\Trim Panel Replacement – Side Front Door) . 3. Remove the radio speaker. Refer to Speaker Replacement – Front Door in Entertainment. 4. Remove the water deflector in order to access the window regulator. Refer to Water Deflector Replacement – Front Door (See: Body and Frame\Doors, Hood and Trunk\Front Door Panel\Service and Repair\Front Door Panel Components\Water Deflector Replacement – Front Door) . Disengage the door glass to the regulator sash channel clips (2). Separate the door glass from the sash channel (1). 6. Push the window to the up position and tape in place. 7. Loosen the power window regulator bolts. Remove the rear regulator bolt. 8. Lift the window regulator, disengaging the loosened bolts from the door. 9. Disconnect the regulator electrical connector. 10. Remove the power window regulator from the door. Installation Procedure
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Automatic Transaxle 2-3 Shift Flare During First Minutes of Driving After Cold Soak (Perform Bulletin Procedure) Models: 2002 Saturn S-Series Vehicles with Automatic Transaxle (RPOs MP6, MP7) Attention: General Manager, Fixed Operations Manager, Parts Manager, Technician Condition: Some customers of 2002 S-series vehicles with MP6 or MP7 automatic transaxles may comment on a 2-3 shift flare during the first few minutes of driving after vehicle cold soak. Cause: This condition may be caused by improper pressure, a leak in the 2nd clutch circuit, improper clutch plate finish on 2nd and 3rd clutches, a restriction in the 3rd clutch oil delivery path in the end cover, or improper surface finish in the piston bores of the 2-3 clutch housing. Correction: To correct this condition, duplicate by cold soaking the vehicle the amount of time at temperature described by the owner. Refer to procedure in this bulletin. Service Procedure Verify proper transaxle pressures by installing gauge and performing stepped pressure test after cold soak. Refer to “Stepped Pressure Test” procedure in the 2002 Saturn S-Series Automatic Transaxle Service Manual. ^ If pressures are low, follow the diagnostic chart for DTC P0745 for possible causes of low pressure. Refer to “P0745 – PC Solenoid Pressure Low” diagnostic in the 2002 Saturn S-Series Automatic Transaxle Service Manual. ^ If pressures are within normal ranges, proceed to Step 2. Remove the transaxle end cover. Refer to “End Cover Replacement” in the 2002 Saturn S-Series Automatic Transaxle Service Manual. Check torque on input shaft nut and end cover 3rd clutch oil passage for restrictions. ^ Input shaft nut torque should be 150 N.m (111 ft-lb). If nut is found to be loose, remove nut, clean threads and install new nut using Service Manual procedures and proceed to check 3rd oil passage. ^ Check 3rd oil passage in the end cover by pouring transaxle fluid through it and another passage. If the passage is restricted, you will notice significantly less fluid flow through it. If 3rd clutch passage is found to be restricted, install new end cover per Service Manual procedures and retest for concern. ^ If nut and 3rd clutch passage are okay, proceed to Step 4. Remove transaxle from vehicle. Refer to “Transaxle Removal” in the 2002 Saturn S-Series Automatic Transaxle Service Manual. Disassemble transaxle and install new 2-3 clutch housing, clutch pistons and clutch plates. Refer to “Transaxle Disassemble” in the 2002 Saturn S-Series Automatic Transaxle Service Manual.
