Engine Saturn SL I

Scheme 2

1. Disconnect negative battery cable and remove coolant recovery bottle cap. Drain coolant. Remove air cleaner assembly and cover throttle body to prevent foreign objects from entering engine.
2. Disconnect and place aside electrical connectors for temperature sensor, O2 sensor, idle air control valve, ignition coil pack, throttle position sensor, MAP sensor and EGR solenoid. Remove brake booster vacuum hose.
3. Remove ground connectors located on upper transaxle-to-engine bolts. Disconnect fuel injector and transaxle harness connectors. Disconnect accelerator cable. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION.
4. Disconnect upper radiator hose at cylinder head. Remove A/C compressor. DO NOT discharge A/C system. Secure A/C compressor to front cross brace.
5. On automatic transaxle equipped models, disconnect and plug transaxle cooler lines. On manual transaxle equipped models, remove clutch hydraulic damper and twist clutch actuator cylinder 1/4 turn counterclockwise to remove. Secure clutch hydraulic system to battery tray.
6. On all models, disconnect shift cable. Secure radiator assembly to front cross brace. Raise and support vehicle. Remove front wheels. Remove front and 2 side splash shields. Remove front brake calipers and secure aside. Remove front strut-to-knuckle bolts.
7. Disconnect lower radiator hose and heater hoses. Disconnect power steering shaft and pressure switch harness connector. Remove front exhaust pipe. On 1991 models, remove engine-to-transaxle stiffening brackets. On all models, remove alternator and starter shields.
8. On automatic transaxle equipped models, remove flexplate cover and remove flexplate-to-torque converter bolts. Disengage brake line from cradle. On 1992 models, place a 1" x 1" x 2" block of wood between engine torque strut bracket on lower front of engine and cradle. (Scheme 2) On 1991 models, remove 3 torque axis mount-to-engine nuts. Torque axis mount is located on upper front of engine.
9. On all models, place power train support dolly under cradle. Use 2 36" lengths of 4" x 4" wood to support cradle on dolly. Remove torque strut-to-cradle brackets. Remove 4 cradle retaining bolts and lower power train assembly from vehicle.
10. Remove spark plug wires. Remove power steering pump and pump bracket, and secure to cradle in an upright position. Attach a suitable engine hoist. Remove front engine mount. Remove starter bracket bolt. Place a block of wood between axle shaft and cradle, and remove axle shaft support bracket-to-engine bolts.
11. On 1992 models, place a block of wood between floor and bottom of transaxle case to support transaxle during engine separation. 1991 models are equipped with a transaxle-to-cradle bracket that serves this purpose. On 1991 engines, remove front engine mount assembly and motion restrictor cable (if equipped). On 1992 engines, lift engine slightly and remove strut bracket and strut.
12. On all models, remove 4 transaxle-to-block bolts. Move engine forward in cradle to separate engine from transaxle. Lift engine assembly from cradle. To install, reverse removal procedure. Fill cooling system. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table at end of article.