GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2000 🢒 L300/LW300 🢒 Body and Accessories 🢒 Frame and Underbody 🢒 Frame Replacement

Tools Required

    • J43628 Frame Alignment Fixture
    • KM671Bushing Remover/Installer
    • KM907 Bushing Remover/Installer
    • KM-907-11
    • KM-907-12
    • KM-907-30
    • SA9140E Torque Angle Gauge

Removal
  1. INSERT GRAPHIC SMGCH 78999AA1

    2. On vehicles equipped with L81 engines, remove the rear exhaust manifold pipe heat shield.

  2. INSERT GRAPHIC SMGCH 78236AA1

    3. Remove the rear transaxle mount through bolt, and the transaxle mount-to-frame bolt.

  3. INSERT GRAPHIC SMGCH 78237AA1

    4. Fasten the radiator to the upper radiator support.

    Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  4. Raise the vehicle on a hoist.
  5. Remove the front wheel and tire assemblies.
  6. INSERT GRAPHIC SMHVC 80580AA1

    7. Remove the right front lower splash shield.

  7. Remove the left front wheel liner push pin from frame.
  8. INSERT GRAPHIC SMGCH 79849AA1

    9. Disconnect the rear O2 sensor connection, and remove the harness from the frame at the attachment points.

  9. INSERT GRAPHIC SMGCH 79007AA1

    10. On L61, remove the O2 sensor clamp to underbody attachment nut.

  10. INSERT GRAPHIC SMGCH 79277AB1

    11. Remove the exhaust manifold pipe on L81 engines, and on L61 engines with a manual transaxle. (L81 shown)

  11. INSERT GRAPHIC SMGCH 79238AA1

    12. Remove the front transaxle mount through bolt.

  12. INSERT GRAPHIC SMGCH 79239AA1

    13. Remove the remaining rear transaxle mount-to-frame bolts.

  13. Remove the rear transaxle mount.
  14. INSERT GRAPHIC SMGCH 79240AB1

    15. Remove the steering gear-to-frame bolts. Discard the bolts and nuts.

  15. On vehicles equipped with L61 engines and automatic transaxle, remove the steering gear heat shield.
  16. Using mechanics wire, secure the steering gear assembly to the body of the vehicle.
  17. INSERT GRAPHIC SMGCH 83521AA1

    18. On L61 with a manual transaxle, remove the frame to shifter link pivot pin clip.

  18. INSERT GRAPHIC SMGCH 79641AA1

    19. Remove the A/C line to frame attachment clip at the front of the vehicle.

    Notice: Hold the ball stud from turning when removing/installing the nut. The boot can become torn and damaged if the ball stud turns.

  19. INSERT GRAPHIC SMGCH 78241AA1

    20. Remove the stabilizer bar links from the strut and discard the nuts.

    Notice: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

  20. INSERT GRAPHIC SMGCH 78230AA1

    21. Remove the lower ball stud bolt and separate the ball stud from the steering knuckle assembly.

  21. INSERT GRAPHIC SMGCH 78242AA1

    22. Remove the suspension support assemblies.

  22. Remove the suspension support cage nuts from the body. Discard the cage nuts and support bolts, as new nuts and bolts must be used for assembly.
  23. INSERT GRAPHIC SMGCH 78303AA1
  24. INSERT GRAPHIC SMGCH 78246AD1

    25. Using powertrain lifting table and the J43628 Frame Alignment Fixture, support frame assembly.

  25. Remove the remaining frame-to-body attachment fasteners.
  26. Carefully lower the frame assembly from the vehicle.
  27. Remove the frame assembly cage nuts from the body. Discard the cage nuts and frame bolts as new nuts and bolts must be used for assembly.

Disassembly
  1. INSERT GRAPHIC SMGCH 78243AA1

    2. Remove the stabilizer clamp-to-frame bolts.

  2. Remove the stabilizer bar and clamps.
  3. INSERT GRAPHIC SMGCH 78244AA1

    4. Remove the control arm-to-frame assembly bolts and discard the bolts.

  4. Remove the control arm from the frame.
  5. INSERT GRAPHIC SMGCH 78245AA1

    6. Using tools KM671Bushing Remover/Installer KM907 Bushing Remover/Installer, KM-907-11, KM-907-12 and KM-907-30, press out the outer 4 damping bushings.

  6. INSERT GRAPHIC SMGCH96230AA

    7. Using Bushing Remover/Installer KM-907, KM-907-11, and KM-907-12 press out the center 2 damping bushings.

Assembly
  1. INSERT GRAPHIC SMGCH78245AA1

    2. Install the outer 4 damping bushings using tool KM-671 along with KM-907-13 and KM-907-14.

  2. INSERT GRAPHIC SMGCH96232AA

    3. Install center 2 damping bushings using tool KM-907-11 and KM-907-22.

  3. INSERT GRAPHIC SMGCH78243AA1

    4. Install the stabilizer bar to the frame assembly.

    Tighten
    Tighten the stabilizer bar clamp-to-frame bolts to 20 N·m (15 lb ft).

    Important: Use new bolts. The torque retention of old bolts may not be sufficient.

  4. Using the SA9140E , install the control arms to frame assembly using new bolts.

    5. Tighten
    Tighten the control arm-to-frame to 90 N·m (66 lb ft) +75-90 degrees.

Installation
  1. INSERT GRAPHIC SMGCH78303AA1

    2. Important: Be sure the frame alignment tool fully engages in all gage holes.

  2. Install NEW cage nuts into the body as torque retention of old nuts may not be sufficient.
  3. Raise the frame assembly to the body.

    4. Important: Do not tighten fastener at this time.

  4. INSERT GRAPHIC SMGCH78246AD1

    5. Install NEW frame-to-body bolts.

  5. INSERT GRAPHIC SMGCH78242AB1

    6. Install NEW cage nuts into the body for the suspension supports, as torque retention of old nuts may not be sufficient.

  6. Install suspension supports using NEW bolts and tighten all frame bolts using SA9140E or equivalent.

    7. Tighten
    Tighten the suspension support-to-body bolts to 90 N·m (66 lb ft) +45-60 degrees.

    Important: Use a new bolt and nut. The torque retention of old fasteners may not be sufficient.

  7. INSERT GRAPHIC SMGCH78230AA1

    8. Install the lower control arm ball stud into the steering knuckle. Hold the bolt stationary while turning the nut.

    Tighten
    Tighten the lower control arm-to-steering knuckle to 100 N·m (75 lb ft).

  8. INSERT GRAPHIC SMGCH83521AA1

    9. On vehicles equipped with L61 and manual transaxle, install the frame to shifter link pivot pin clip.

  9. INSERT GRAPHIC SMGCH78240AB1

    10. Install the steering gear-to-frame using new bolts and nuts and tighten using SA9140E or equivalen).

    Tighten
    Tighten the steering gear-to-frame to 45 N·m (35 lb ft) +90 degrees.

  10. On vehicles equipped with an L61 engine and automatic transaxle, install steering gear heat shield.

    11. Tighten
    Tighten the steering gear heat shield-to-frame to 7 N·m (35 lb in).

    Notice: Hold the ball stud from turning when removing/installing the nut. The boot can become torn and damaged if the ball stud turns.

  11. INSERT GRAPHIC SMGCH78241AA1

    12. Using new nuts, install the stabilizer bar link-to-strut assembly.

    Tighten
    Tighten the stabilizer bar link-to-strut to 65 N·m (48 lb ft).

  12. Inspect the rubber boots for damage and replace the boots if damaged.
  13. INSERT GRAPHIC SMGCH7839AA1

    14. Install the rear transaxle mount.

  14. Install the 2 rear transaxle mount to frame bolts.

    15. Tighten
    Tighten the rear transaxle mount-to-frame bolts to 60 N·m (44 lb ft).

  15. INSERT GRAPHIC SMGCH78238AA1

    16. Install the front transaxle mount through bolt.

    Tighten
    Tighten the front transaxle mount through bolt to 55 N·m (41 lb ft).

  16. INSERT GRAPHIC SMGCH78277AB1

    17. Install the exhaust manifold pipe on L81 engines and on L61 engines with manual transaxles. (L81 shown)

  17. Tighten exhaust manifold pipe to exhaust manifold.

    18. Tighten
    Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N·m (22 lb ft).

  18. Tighten the exhaust manifold pipe to exhaust pipe.

    19. Tighten
    Tighten the exhaust manifold pipe-to-pipe bolts to 20 N·m (15 lb ft).

  19. INSERT GRAPHIC SMGCH79007AA1

    20. On L61, install the O2 sensor clamp to underbody attachment nut.

    Tighten
    Tighten the O2 sensor clip-to-underbody attachment nut to 4 N·m (35 lb in).

  20. INSERT GRAPHIC SMGCH79641AA1

    21. Reattach the A/C line clip to the front of the frame assembly.

  21. INSERT GRAPHIC SMHVC80580AA1

    22. Install the right front lower splash shield.

    Tighten
    Tighten the right splash shield-to-body to 5 N·m (44 lb in).

  22. Install the left front wheel liner push pin to frame.

    23. Notice: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel nuts to loosen in service.

  23. INSERT GRAPHIC SMGCH79894AA1

    24. Connect the O2 sensor electrical connector and reattach the harness to the frame.

  24. Position the wheel onto the hub.
  25. Install the wheel bolts and tighten in a crisscross pattern.
    26. • Hand tighten all five wheel bolts.
    • Use a torque wrench to tighten the wheel bolts using a crisscross pattern.

    Tighten
    Tighten the wheel bolts -- initial torque to 63 N·m (46 lb ft).

    • Use a torque wrench to final tighten the wheel bolts using a crisscross pattern.

    Tighten
    Tighten the wheel bolts -- final torque to 125 N·m (92 lb ft).

    • Lower the vehicle from the hoist.
  26. INSERT GRAPHIC SMGCH78236AA1

    27. Install the remaining rear transaxle mount to frame bolt.

    Tighten
    Tighten the rear transaxle mount-to-frame bolts to 60 N·m (44 lb ft).

  27. Install the rear transaxle mount through bolt and heat shield, on vehicles equipped with 4-cylinder engine and automatic transaxle.

    28. Tighten
    Tighten the rear transaxle mount through bolt to 90 N·m (66 lb ft).

  28. INSERT GRAPHIC SMGCH78999AA1

    29. On vehicles equipped with L81 engines, install the exhaust manifold pipe heat shield.

    Tighten
    Tighten the exhaust manifold pipe heat shield bolts (L81) to 8 N·m (71 lb in).

  29. Perform the vehicle alignment. Refer to Alignment procedure in the Alignment, Wheels and Tires section in this service manual.