Repair manual
Saturn SL I Repair Manual
Step-by-step repair and maintenance instructions for the Saturn SL I (1990–1995): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
64sections
405articles
ENManual language
- IDENTIFICATION
- DESCRIPTION & OPERATION
- SERVICE PRECAUTIONS
- SPECIAL TOOLS
- DISABLING & ACTIVATING AIR BAG SYSTEM
- POST-COLLISION INSPECTION
- SIR COIL ASSEMBLY
- DISPOSAL PROCEDURES
- DEPLOYED AIR BAG
- UNDEPLOYED AIR BAG - FAULTY UNIT
- SCRAPPED VEHICLE
- Procedure 1: Deployment Inside Vehicle
- Procedure 2: Deployment Outside Vehicle
- POST-COLLISION AIR BAG SAFETY INSPECTION
- REMOVAL & INSTALLATION
- Removal
- Installation
- DISCRIMINATING SENSOR
- TESTING - SYSTEM OPERATION CHECK
- WIRE REPAIR
- CONNECTOR REPAIR
- PIGTAIL WIRE REPAIR
- TORQUE SPECIFICATIONS
- DIAGNOSIS & TESTING
- DIAGNOSTIC PROCEDURE
- DIAGNOSTIC CODES
- SYSTEM TESTING - DIAGNOSTIC CHARTS
- SIR DIAGNOSTIC SYSTEM CHECK
- Circuit Description
- DIAGNOSTIC AIDS
- Description
- Test Conditions
- Failure Conditions
- Action Taken
- Conditions To Clear
- APPLICATION
- IDENTIFICATION
- DESCRIPTION
- ATF Temperature Sensor
- Brake Switch
- Ignition Signal
- Master Enable Relay
- Mode Switch
- Neutral Switch Signal
- PCM Diagnostic Connector
- Turbine Speed Signal
- Vehicle Speed Sensor
- Line Actuators
- SERVICE ENGINE SOON Light
- SHIFT TO D2 Light
- SELF-DIAGNOSTICS
- Hard Failures
- Intermittent Failures
- Malfunction History & Information Flags
- READING TROUBLE CODES
- RETRIEVING CODES
- TROUBLE CODES & INFORMATION FLAGS
- CLEARING CODES
- PCM LEARN MODE
- ACTUATOR QUICK CHECK
- CODE CHARTS
- Diagnostic Charts
- Diagnostic Aids
- INFORMATION FLAG CHARTS
- THM 3T40 APPLICATION
- THM 4L60/700-R4 APPLICATION (1991-92)
- THM 4T60 & 4T60-E APPLICATION (1991-92)
- THM 4L80-E APPLICATION
- THM 4L80-E SERIES CODE DESIGNATION
- MP6 & MP7 APPLICATIONS (1991-92)
- DIAGNOSTIC FLOW
- DESCRIPTION
- TCC CONTROL COMPONENTS
- Brake Switch
- Coolant Temperature Sensor
- Electronic Control Module (ECM)
- TCC Solenoid Assembly
- Throttle Position Sensor (TPS)
- Vacuum Sensor
- Vehicle Speed Sensor (VSS)
- 3rd & 4th Gear Switches
- TROUBLE SHOOTING
- Problem In Electronic Control Module
- Electrical Problems
- Valve Body Assembly
- Oil Pump Assembly
- CONVERTER CLUTCH APPLY SLIPS, ROUGH OR SHUDDERS
- CONVERTER CLUTCH DOES NOT RELEASE
- DIAGNOSTIC TOOLS
- RETRIEVING TROUBLE CODES
- CLEARING TROUBLE CODES (EXCEPT SATURN)
- CLEARING TROUBLE CODES (SATURN)
- ENTERING SELF-DIAGNOSTICS
- EXITING SELF-DIAGNOSTICS
- DISPLAYING TROUBLE CODES
- CLEARING TROUBLE CODES
- SYSTEM SELECTION
- TEST TYPE SELECTION
- CLEAR CODES
- DATA
- INPUTS
- OUTPUTS
- OVERRIDE
- SNAPSHOT
- EXPLANATION OF SPECIFIC TEST SELECTION
- SPECIFIC TEST SELECTION
- BCM Snapshot
- ECM Snapshot
- STATUS LIGHT INDICATORS
- ECM
- HIGH
- MED
- LOW
- OFF or VENT
- Left-Side AUTO
- °C
- Upper Arrow (Icon)
- BCM
- Lower Arrow (Icon)
- TCC LOCK-UP PROBLEMS
- NO LOCK-UP CONDITION
- BRAKE SWITCH TEST
- CHECKING SELF-DIAGNOSTIC SYSTEM
- TCC APPLY SOLENOID TEST
- NO TCC RELEASE CONDITION
- CHECKING VOLTAGE TO TERMINAL "A" AT TRANSMISSION USING ALDL
- CHECKING VOLTAGE TO TERMINAL "A" AT TRANSMISSION
- CHECKING FOR GROUND AT TERMINAL "D" AT TRANS. USING ALDL
- CHECKING FOR GROUND AT TERMINAL "D" AT TRANSMISSION
- COOLER LINE PRESSURE TEST
- ELECTRICAL SWITCHES TEST
- Single Terminal Switch (8642473) & 2 Terminal Switch
- Single Terminal Switch (8642569 & 8634475) & 2 Terminal
- GROUNDING "D" WIRE AT TRANSMISSION USING ALDL
- SELF-DIAGNOSTIC SYSTEM CHECK REATTA & RIVIERA
- Always Start Electrical Or Electronic Diagnosis Here
- Diagnostic Aids
- CHART A-2, SERVICE ENGINE SOON LIGHT WON'T GO OUT OR FLASH (REATTA & RIVIERA)
- CHART B-1, BCM POWER & GROUNDS - REATTA & RIVIERA
- CHART C, ECCP DISPLAY PROBLEMS (LOSS OF ECCP COMMUNICATIONS) (REATTA & RIVIERA)
- CHART D-2, SERIAL DATA CIRCUIT SHORTED TO VOLTAGE - REATTA & RIVIERA
- CHART A-2, SERVICE ENGINE SOON LIGHT WILL NOT GO OUT OR FLASH - TORONADO & TROFEO
- SELF-DIAGNOSTIC SYSTEM CHECK (NON-CRT TORONADO & TROFEO)
- CHART C, LOSS OF ECCP COMMUNICATIONS (NON-CRT EQUIPPED TORONADO & TROFEO)
- CHART D, LOSS OF COMMUNICATIONS (NON-CRT EQUIPPED TORONADO & TROFEO)
- CHART D-2, SERIAL DATA CIRCUIT SHORTED TO VOLTAGE (NON-CRT EQUIPPED TORONADO & TROFEO)
- CHART C, COLOR CRT UNABLE TO CONTROL ECCP (CRT EQUIPPED TORONADO & TROFEO)
- CHART D, SERIAL DATA CIRCUIT OPEN (CRT EQUIPPED TORONADO & TROFEO)
- CHART D-1, GROUNDED SERIAL DATA CIRCUIT (CRT EQUIPPED TORONADO & TROFEO)
- CHART E, COLOR CRT ABNORMALITIES (CRT EQUIPPED TORONADO & TROFEO)
- Note On Intermittents
- CODE 23, MAT SENSOR SIGNAL VOLTAGE HIGH
- CODE 26, DIAGNOSTIC CIRCUIT CHECK
- SERVICE ENGINE SOON LIGHT INOPERATIVE
- SERVICE ENGINE SOON LIGHT WON'T GO OUT OR FLASH CODE 12
- Hot Light Diagnosis
- QDM CIRCUITS
- Hot Light Diagnosis (C Body)
- CODE 27 OR 28, GEAR SWITCH CIRCUITS - 3.3L WITH 3T40 TRANSAXLE
- CODE 28 OR 29, GEAR SWITCH CIRCUITS - 3.3L A BODY WITH 4T60
- CODE 31, PARK/NEUTRAL SWITCH CIRCUIT - 3.3L & 3.8L
- Poor Connection or Damaged Harness
- Intermittent Test
- CODE 39, TCC CIRCUIT 3.3L WITH 3T40 TRANSAXLE
- CODE 39, TCC CIRCUIT 3.3L & 3.8L WITH 4T60 (440-T4) TRANSAXLE
- CHART C-8, TORQUE CONVERTER CLUTCH ELECTRICAL DIAGNOSIS - 3.1L PFI A & J BODIES (2 OF 2)
- 1st Gear
- 2nd Gear
- 3rd Gear
- CHART C-8C, 4T60 TRANSAXLE 1ST GEAR SWITCH ELECTRICAL DIAGNOSIS - 3.4L PFI W BODY
- CHART C-8B, 4T60 TRANSAXLE SHIFT SOLENOID FUNCTIONAL CHECK - 1991 E BODY (EXCEPT ELDORADO) 3.8L PFI (VIN L)
- Transaxle Prefunctional Check
- No Indicator Lights On Or Ignition Indicator Light Only On
- Battery Indicator Light On, All Other Indicator Lights Off
- Brake Indicator Light Not On
- Shift "A" And/Or Shift "B" Indicator lights Not On
- Converter Clutch Apply Indicator Light On All The Time
- Converter Clutch MOD Indicator Light On All the Time
- CHART C-8B, 4T60 TRANSAXLE SHIFT SOLENOID FUNCTIONAL CHECK - 3.8L PFI (VIN L & 1) 1992
- CHART C-8A, TORQUE CONVERTER CLUTCH FUNCTIONAL CHECK - 1992 3.8L PFI (VIN 1)
- CHART C-8B, 4T60 TRANSAXLE SHIFT SOLENOID FUNCTIONAL CHECK - 1992 3.8L PFI (VIN 1)
- Diagnostics Aids
- CODE 23, MAT SENSOR TEMP. LOW - 1991 2.5L & 4.3L TURBO
- CODE 25, MAT SENSOR TEMP. HIGH - 1991 2.5L & 4.3L TURBO
- CODE 25, MAT SENSOR TEMP. HIGH - 1992 2.5L & 4.3L TURBO
- CODE 53, SYSTEM VOLTAGE HIGH - LT. TRUCK
- Notes On Intermittents
- CODE 59, TRANSMISSION TEMPERATURE SENSOR CIRCUIT (LOW TEMPERATURE INDICATED) - LT. TRUCK
- CODE 75, SYSTEM VOLTAGE LOW - LT. TRUCK
- CODE 83, TCC QDM FAULT - LT. TRUCK
- CODE 86, SHIFT SOLENOID "B" STUCK "ON" - LT. TRUCK
- CODE 87, SHIFT SOLENOID "B" STUCK "OFF" - LT. TRUCK
- TORQUE CONVERTER CLUTCH CIRCUIT CHECK - LT. TRUCK
- SHIFT SOLENOID "A" CIRCUIT CHECK - LT. TRUCK
- SHIFT SOLENOID "B" CIRCUIT CHECK - LT. TRUCK
- FORCE MOTOR CIRCUIT CHECK (LT. TRUCK)
- APPLICATION
- IDENTIFICATION
- DESCRIPTION
- LUBRICATION
- ADJUSTMENTS
- ON-VEHICLE SERVICE
- DRIVE AXLE SHAFTS
- OIL COOLER FLUSHING
- Removal
- Installation
- VALVE BODY
- TROUBLE SHOOTING
- PCM LEARN MODE
- QUICK CHECK
- SYMPTOM DIAGNOSIS
- Fluid Out Of Vent Or Foaming
- No Reverse
- Harsh Upshifts
- Vehicle Moves In Park
- Vehicle Stuck In Park
- High Line Pressure
- Low Line Pressure
- No 1st Gear
- 2nd Gear Stuck ON
- No 2nd Gear
- No 3rd Gear
- No 4th Gear
- No Drive In Any Gear
- No TCC Apply
- TCC Stuck On (Engine Stops)
- TORQUE CONVERTER
- STALL SPEED TEST
- INSPECTION
- END PLAY CHECK
- ELECTRONIC SELF-DIAGNOSTICS & ELECTRONIC TESTING
- ROAD TEST
- Gear Selector Position "D4" (Overdrive)
- With Saturn Portable Diagnostic Tool (PDT)
- Without Saturn Portable Diagnostic Tool (PDT)
- REMOVAL & INSTALLATION
- TRANSAXLE DISASSEMBLY
- COMPONENT DISASSEMBLY & REASSEMBLY
- Cleaning & Inspection
- Bearing & Seals
- Parking Pawl Assembly
- Disassembly & Reassembly
- Disassembly & Inspection
- Reassembly
- Disassembly
- TRANSAXLE REASSEMBLY
- Case Assembly
- Differential End Play
- TRANSAXLE SPECIFICATIONS
- TORQUE SPECIFICATIONS