Filed Under (Saturn) by admin on 16-09-2010
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1. Remove transaxle as outlined under “Transaxle, Replace.” Refer to Transaxle Replace. 2. Remove release fork and bearing from transaxle by unsnapping fork from ball stud. 3. Slide release bearing from release fork, then check release bearing for excessive play or minimal drag, replace as required. Do not wash bearing in solvent. 4. Using a feeler gauge, measure between pressure plate and flywheel; 0.205-0.287 inch should be indicated. If not, replace clutch disc. 5. Remove pressure plate to flywheel attaching bolts in progressive crisscross pattern. 6. Remove pressure plate and clutch disc. 7. Inspect pressure plate for excessive wear, chatter marks, cracks or overheating; replace as required. Random black spotting on friction surface is normal. 8. Using a straightedge and feeler gauge, measure pressure plate warpage. Maximum warpage is 0.006 inch. 9. Inspect clutch disc for oil, burnt spots, loose damper springs, hub and rivets; replace as required. 10. Measure flywheel thickness. Minimum thickness is 1.102 inch; replace as required. 11. Using a dial indicator, measure flywheel runout. Push crankshaft forward to take up thrust bearing clearance. Maximum runout is 0.006 inch; replace as required. 12. Remove flywheel to crankshaft attaching bolts, then flywheel. INSTALLATION 1. Install flywheel to crankshaft attaching bolts, then torque in order, to 59 ft. lbs. 2. Install clutch disc and pressure plate, with pressure plate yellow dot aligned with flywheel mark, then start pressure plate to flywheel bolts. 3. Install clutch disc alignment tool No. SA9145T or equivalent, until bottoms out in crankshaft. 4. Torque bolts in crisscross pattern to 18 ft. lbs. 5. Remove clutch alignment tool, then install fork clip. 6. Lube fork pivot using high temperature grease part No. 21005995 or equivalent, then install release bearing to fork. Do not lube release bearing or quill. 7. Install release fork and bearing to ball stud.
Filed Under (Saturn) by admin on 27-08-2010
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Hydraulic Clutch Control System IMPORTANT: The clutch hydraulic system is to be serviced as a COMPLETE UNIT!!!. It is a sealed unit and has been filled with fluid and bled of air at the factory. Individual components of the system are not available for service, except the slave cylinder actuator pushrod plastic retainer strap. Do not attempt to bleed the clutch hydraulic system. The bleed screw located on the clutch hydraulic slave cylinder is used for the factory fluid fill only. WARNING: Do not attempt to bleed the clutch hydraulic unit. Any observed fittings are there for factory use only. The unit comes as a complete pre-bled unit. REMOVAL 1. 2. 3. 4. 5. 6. 7. Block clutch pedal up to prevent pedal from being depressed with slave cylinder removed from transaxle. Remove air induction system. Disconnect negative battery cable from battery. Disconnect positive battery cable from battery Remove hold-down retaining nut and screw, and lift off battery hold-down retainer. Lift the battery of vehicle, and place in a safe location. Remove battery tray bolts and tray. IMPORTANT: One bolt is located in the fender well. NOTICE: Removal of the hydraulic damper with a power tool prior to removal of the actuator could result in breaking off the hydraulic line. IMPORTANT: Prior to removing the slave cylinder from the clutch housing, make sure that the clutch hydraulic system has sufficient fluid. Refer to the “Clutch Hydraulic Fluid Check” procedures in this manual. (This is not necessary if the clutch hydraulic system is being removed to be replaced.) 8. Rotate actuator 1/4 turn counterclockwise while pushing toward housing in order to disengage the bayonet connector and remove from clutch housing. 9. Remove two hydraulic damper to clutch housing nuts and slide damper and bracket assembly off studs.
Filed Under (Saturn) by admin on 04-07-2010
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1. Remove shroud fasteners (5.5 mm hex head) and remove steering column upper shroud panel. 2. Insert key into ignition lock cylinder and rotate to ACC position. 3. Depress the square locking button on the top of ignition module assembly and slide lock cylinder assembly from ignition module housing. INSTALLATION IMPORTANT : Actuator blade within ignition module housing must be in the ACC position to install lock cylinder assembly. If rotated, replace it to the ACC position using needle nose pliers. Installation is the reverse of Removal. Note: Make sure locking button locks into opening lock cylinder module. Torque steering column lower trim cover bolts to 26 in.lbs. (3 Nm)
