GM Prizm/Nova 1985-1993 Repair Guide

Automatic Transaxle

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REMOVAL & INSTALLATION



1985-88 VIN Code 4 Engine With A131L Transaxle

See Figures 1 and 2

  1. Disconnect the negative battery cable
  2.  
  3. Remove the air intake tube.
  4.  
  5. Disconnect the speedometer cable and neutral start wiring connector at the transaxle. Loosen the lug nuts on the left front wheel.
  6.  
  7. Disconnect the thermostat housing at the transaxle.
  8.  
  9. Disconnect the ground cable at the transaxle.
  10.  
  11. Remove 1 upper mount to bracket bolt.
  12.  
  13. Label and disconnect any interfering wiring in the area of the transaxle case.
  14.  
  15. Disconnect the throttle valve cable at the carburetor.
  16.  
  17. Remove 2 upper bellhousing bolts.
  18.  
  19. Support the engine using either GM tool J-28467-A or equivalent.
  20.  
  21. Raise the vehicle and support it safely on stands.
  22.  
  23. Remove the left front wheel.
  24.  
  25. Remove the splash shields under the car.
  26.  
  27. Remove the center beam.
  28.  
  29. Disconnect the shift cable at the transaxle.
  30.  
  31. Remove the shift cable bracket.
  32.  
  33. Remove the cooler bracket and disconnect the cooler lines at the transaxle. Plug the lines to prevent leakage.
  34.  
  35. Remove the inspection cover on the bell housing and remove the torque converter bolts through the inspection hole.
  36.  
  37. Disconnect the left control arm at the ball joint.
  38.  
  39. Disconnect the right control arm at the ball joint.
  40.  
  41. Remove the right and left axle shafts from the transaxle.
  42.  
  43. Disconnect the starter bolts
  44.  
  45. Remove the 3 rear transaxle bolts.
  46.  
  47. Support the transaxle with a floor jack.
  48.  
  49. Remove the remaining mount bolts and remove the remaining bellhousing bolts.
  50.  
  51. Remove the transaxle from the vehicle. Handle the unit carefully and do not allow it to tip; the torque converter may fall from the unit and become damaged.
  52.  

To install:
  1. Before reinstallation, install the torque converter in the transaxle. If the converter has been drained, refill it with 2.3 US qts. of Dexron®II ATF. Refer to the Capacities Chart in Routine Maintenance .
  2.  
  3. Check the torque converter installation. Use a straightedge and calipers to check the distance between the face of the converter and the surface of the transaxle housing. Correct free space is more than 20mm.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Measuring converter to case clearance

  1. Apply multi-purpose grease to the contact points of the torque converter and the crankshaft.
  2.  
  3. Place the transaxle on the jack and lift into position. Align the guide pin with 1 of the holes in the driveplate (flywheel) and align the 2 pins on the block with the converter housing holes. Temporarily install 1 bolt to hold everything together.
  4.  
  5. Install all of the transaxle housing bolts and tighten them. The larger bolts (12mm) should be tightened to 47 ft. lbs. and the smaller (10mm) bolts tightened to 34 ft. lbs.
  6.  
  7. Install the left engine mount and tighten the bolts to 38 ft, lbs.
  8.  
  9. Install the 6 torque converter bolts. Remove the guide pin and install the white bolt, then install the 5 yellow bolts. Tighten the bolts evenly and to 13 ft. lbs.
  10.  
  11. Install the inspection plate (engine rear cover plate).
  12.  
  13. Reinstall the starter.
  14.  
  15. Connect the drive shafts to the transaxle.
  16.  
  17. Install the center engine support and tighten the bolts to 29 ft. lbs.
  18.  
  19. Install the front and rear mounts, tightening the 4 bolts to 29 ft. lbs.
  20.  
  21. Connect the left and right control arms to the ball joints.
  22.  
  23. Reinstall the thermostat housing.
  24.  
  25. Connect the oil cooler lines to the transaxle.
  26.  
  27. Connect and adjust the shift control cable.
  28.  
  29. Install the speedometer cable.
  30.  
  31. Install and adjust the throttle valve cable.
  32.  
  33. Connect the neutral start switch connector. Connect or reposition any wiring which was moved to gain access during removal.
  34.  
  35. Install the air cleaner.
  36.  
  37. Fill the transaxle with the correct amount of Dexron®II ATF. If the transaxle has been disassembled and drained, install 5.8 US qts. If the transaxle was not disassembled and still contains fluid, add 2.4 US qts.
  38.  
  39. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  40.  
  41. Install the splash shields below the engine. Install the left front wheel and lower the vehicle to the ground.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Start the engine and allow it to idle. With the wheels blocked front and rear and your foot on the brake, engage each gear and check that the transaxle engages properly. Check that the car will not roll in PARK .
  46.  
  47. Allow the engine to idle with the transaxle in PARK ; check the fluid level on the dipstick. Check all assembly points for any sign of leakage.
  48.  



Click image to see an enlarged view

Fig. Fig. 2: Using tool J-28467 to support the engine. An external hoist may be used but raising and lowering the car becomes difficult

1988 VIN Code 5 Engine With A240E Transaxle

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Disconnect the neutral start switch.
  6.  
  7. Disconnect the solenoid valve wiring connector.
  8.  
  9. Disconnect the speed sensor.
  10.  
  11. Disconnect the speedometer cable.
  12.  
  13. Remove the water inlet assembly.
  14.  
  15. Remove the throttle cable from the throttle linkage.
  16.  
  17. Remove the transaxle dipstick tube.
  18.  
  19. Disconnect the battery ground cable from the transaxle housing.
  20.  
  21. Loosen, but do not remove the lug nuts on the left front wheel. Raise the vehicle and safely support it.
  22.  
  23. Drain the transaxle oil.
  24.  
  25. Remove the splash shields from under the engine.
  26.  
  27. Remove the shift control cable and brackets.
  28.  
  29. Disconnect the oil cooler lines at the transaxle. Plug the lines to prevent leakage.
  30.  
  31. Remove the front and rear engine mount bolts.
  32.  
  33. Remove the center engine mount member.
  34.  
  35. Carefully disconnect the oxygen sensor connector and remove the front exhaust pipe.
  36.  
  37. Disconnect and remove the left and right driveshafts from the transaxle.
  38.  
  39. Remove the left front wheel.
  40.  
  41. Remove the cotter pin, lock nut cap, lock nut and washer.
  42.  
  43. Remove the brake caliper assembly and support it with stiff wire out of the way. Do not disconnect the hose. Do not allow the caliper to hang by the hose.
  44.  


CAUTION
Brake pads and shoes contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from brake surfaces! When cleaning brakes, use commercially available brake cleaning fluids.

  1. Remove the brake disc.
  2.  
  3. Remove the steering knuckle from the lower control arm.
  4.  
  5. Remove the left driveshaft.
  6.  
  7. Remove the starter motor and the bracket (stiffener plate).
  8.  
  9. Remove the engine rear cover plate (inspection plate).
  10.  
  11. Remove the torque converter mounting bolts.
  12.  
  13. Lower the vehicle to the ground.
  14.  
  15. Support the engine using GM tool J-28467 or equivalent.
  16.  
  17. Remove the 3 bolts from the rear engine mount.
  18.  
  19. Raise and safely support the vehicle. Remember that the engine support is in place; make necessary adjustments during jacking.
  20.  
  21. Support the transaxle with a jack. Remove the transaxle, keeping it level.
  22.  
  23. Remove the torque converter.
  24.  

To install:
  1. Before reinstallation, install the torque converter in the transaxle. If the converter has been drained, refill it with 2.3 US qts. of Dexron®II ATF. Refer to the Capacities Chart in Routine Maintenance .
  2.  
  3. Check the torque converter installation. Use a straightedge and calipers to check the distance between the face of the converter and the surface of the transaxle housing. Correct free space is more than 20mm.
  4.  
  5. Apply multi-purpose grease to the contact points of the torque converter and the crankshaft.
  6.  
  7. Place the transaxle on the jack and lift into position. Use a guide pin to align the holes in the driveplate (flywheel) and align the 2 pins on the block with the converter housing holes. Temporarily install 1 bolt to hold everything together.
  8.  
  9. Install all of the transaxle housing bolts and tighten them. The larger bolts (12mm) should be tightened to 47 ft. lbs. and the smaller (10mm) bolts tightened to 34 ft. lbs.
  10.  
  11. Install the 3 engine rear mount bolts and tighten them to 38 ft. lbs.
  12.  
  13. Install the 6 torque converter bolts. Remove the guide pin and install the white bolt, then install the 5 yellow bolts. Tighten the bolts evenly and to 20 ft. lbs.
  14.  
  15. Install the inspection plate (engine rear cover plate).
  16.  
  17. Reinstall the stiffener plate and the starter.
  18.  
  19. Install the left driveshaft with its washer, lock nut, lock nut cap and cotter pin.
  20.  
  21. Reconnect the steering knuckle to the lower control arm.
  22.  
  23. Install the brake disc. Install the caliper and tighten the mounting bolts to 18 ft. lbs.
  24.  
  25. Install the left front wheel; tighten the wheel nuts to 76 ft. lbs.
  26.  
  27. Connect both driveshafts to the transaxle.
  28.  
  29. Reinstall the front exhaust pipe using new gaskets. Connect the wiring to the oxygen sensor.
  30.  
  31. Install the engine center mounting member. Tighten the bolts to 29 ft. lbs.
  32.  
  33. Install the bolts for the front and rear engine mounts. Correct torque is 29 ft. lbs. When the mount bolts are secure, the engine support apparatus may be removed.
  34.  
  35. Connect the oil cooler lines to the transaxle.
  36.  
  37. Install the shift control cable and brackets.
  38.  
  39. Replace the splash shields under the engine.
  40.  
  41. Lower the vehicle to the ground.
  42.  
  43. Connect the ground strap to the transaxle housing.
  44.  
  45. Install the transaxle dipstick tube.
  46.  
  47. Install the water inlet assembly.
  48.  
  49. Attach the throttle cable to the linkage and adjust as necessary.
  50.  
  51. Install the speedometer cable and the speed sensor.
  52.  
  53. Connect the wiring to the solenoid valve.
  54.  
  55. Connect the wiring to the neutral start switch.
  56.  
  57. Install the air cleaner.
  58.  
  59. Fill the transaxle with the correct amount of Dexron® II ATF. If the transaxle has been disassembled and drained, install 7.6 US qts. If the transaxle was not disassembled and still contains fluid, add 3.1 US qts. Refer to the Capacities Chart in Routine Maintenance .
  60.  
  61. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  62.  
  63. Connect the negative battery cable.
  64.  
  65. Start the engine and allow it to idle. With the wheels blocked front and rear and your foot on the brake, engage each gear and check that the transaxle engages properly. Check that the car will not roll in PARK .
  66.  
  67. Allow the engine to idle with the transaxle in PARK ; check the fluid level on the dipstick. Check all assembly points for any sign of leakage.
  68.  

1989-92

See Figures 1 and 2

  1. Support the engine with GM tool J-28467-A or equivalent.
  2.  
  3. Remove the battery hold-down, battery and tray.
  4.  
  5. Remove the air cleaner assembly
  6.  
  7. Disconnect the connector at the neutral start switch.
  8.  
  9. Disconnect the ground strap from the transaxle case.
  10.  
  11. Remove the throttle cable from the throttle body.
  12.  
  13. Disconnect the cooling lines at the transaxle and plug the lines to prevent leakage.
  14.  
  15. Remove the shift cable retainer and end clip.
  16.  
  17. Remove the shift cable from its brackets and place the cable out of the way.
  18.  
  19. Remove the upper shift cable bracket from the transaxle housing.
  20.  
  21. Remove the left transaxle mount brace.
  22.  
  23. Remove the through bolt in the mount.
  24.  
  25. Remove the 2 upper transaxle-to-engine bolts.
  26.  
  27. Remove the upper starter bolts.
  28.  
  29. Disconnect the speedometer cable.
  30.  
  31. Raise the vehicle and safely support it.
  32.  
  33. Remove the splash shields from below the car.
  34.  
  35. Drain the transaxle oil.
  36.  
  37. Disconnect the electrical connections to the starter. Remove the bottom starter bolt and remove the starter.
  38.  
  39. Remove the driveshafts from the transaxle.
  40.  
  41. Remove the 3 bolts holding the center crossmember to the radiator support.
  42.  
  43. Remove the covers from the front and center mount bolts; remove the 2 front mount bolts, then the 2 center mount bolts.
  44.  
  45. Remove the 2 nuts from the rear mount.
  46.  
  47. Remove the 2 bolts holding the center crossmember to the main crossmember.
  48.  
  49. Remove the 3 nuts holding the exhaust hanger bracket and remove the bracket.
  50.  
  51. Use a floor jack to support the main crossmember. Check its placement carefully so that the crossmember will be balanced during removal.
  52.  
  53. Remove the 8 bolts holding the main crossmember to the underbody.
  54.  
  55. On the left and right sides, remove the 2 bolts holding the control arm bracket to the underbody.
  56.  


CAUTION
Lower the main crossmember slowly while holding onto the center crossmember. The center crossmember is free to fall at this point and could cause serious injury or damage.

  1. At the front mount, remove the through bolt and the mount.
  2.  
  3. Remove the front mount bracket from the transaxle.
  4.  
  5. Remove the center mount from the transaxle with its 2 bolts.
  6.  
  7. Remove the torque converter bolt shield and remove the bolts holding the torque converter to the flywheel.
  8.  
  9. Remove the 2 bolts holding the lower transaxle mount to the bracket.
  10.  
  11. Lower the vehicle to the ground.
  12.  
  13. Remove the remaining transaxle mount-to-bracket bolt.
  14.  
  15. Adjust the engine support apparatus to lower the transaxle and gain clearance for removal.
  16.  
  17. Disconnect the transaxle mount.
  18.  
  19. Raise and safely support the vehicle.
  20.  


WARNING
The engine support apparatus has been repositioned and the crossmembers are removed. Be very careful when raising the car.

  1. Use a floor jack to support the transaxle. Make sure it is properly positioned.
  2.  
  3. Remove the front and rear lower bolts holding the transaxle to the engine.
  4.  
  5. Carefully remove the transaxle, keeping it as level as possible. Remove the torque converter.
  6.  

To install:
  1. Before installing the transaxle, make sure that the torque converter is all the way into the pump and bushing. Use a straightedge across the front of the transaxle case and measure the inset to the converter. Clearance must be at least 20mm.
  2.  
  3. Lightly coat the converter to flywheel contact point with multi-purpose grease.
  4.  
  5. Support the transaxle on the floor jack and move it into place. Install the transaxle and hold it in place with the front and rear lower transaxle-to- engine bolts. Tighten the bolts snugly; they will be final tightened later.
  6.  
  7. Remove the jack from under the transaxle.
  8.  
  9. Install the starter and its lower bolt snugly. Connect the starter wiring.
  10.  
  11. Lower the vehicle to the ground.
  12.  


WARNING
The engine support apparatus has been repositioned and the crossmembers are removed. Be very careful when moving the car.

  1. Install the left transaxle mount.
  2.  
  3. Install the bolt for the upper mount bracket and the 2 bolts for the lower bracket snugly.
  4.  
  5. Adjust the engine support apparatus to raise the transaxle into position.
  6.  
  7. Install the through bolt for the transaxle mount and tighten it to 64 ft. lbs. Tighten the upper transaxle mounting bracket bolt to 45 ft. lbs.
  8.  
  9. Install the brace at the mount and tighten the bolts to 13 ft. lbs.
  10.  
  11. Install the 2 upper transaxle-to-engine bolts snugly.
  12.  
  13. Install the upper starter bolt snugly.
  14.  
  15. Tighten all the transaxle-to-engine bolts to 34 ft. lbs.
  16.  
  17. Tighten the upper starter bolt to 29 ft. lbs.
  18.  
  19. Install the speedometer cable.
  20.  
  21. Install the upper shift cable bracket, position the shift cable into the bracket and install the cable retainer and end clips.
  22.  
  23. Install the oil cooling lines.
  24.  
  25. Connect the throttle cable at the throttle body.
  26.  
  27. Install the ground strap to the transaxle case.
  28.  
  29. Install the connector to the neutral start switch.
  30.  
  31. Install the air cleaner assembly.
  32.  
  33. Raise and safely support the vehicle.
  34.  
  35. Tighten the 2 lower transaxle mount bolts to 45 ft. lbs.
  36.  
  37. Tighten the lower starter bolt to 29 ft. lbs.
  38.  
  39. Install the torque converter to flywheel bolts and tighten them to 31 ft. lbs.
  40.  
  41. Install the converter bolt shield.
  42.  
  43. Install the center mount with 2 bolts to the transaxle; tighten the bolts to 45 ft. lbs.
  44.  
  45. Install the front mount bracket on the transaxle and tighten the bolts to 13 ft. lbs.
  46.  
  47. Install the front mount. Loosely install the through bolt.
  48.  

As the front mount is installed, the weight on the mount must go towards the transaxle; this allows the mount to align properly.

  1. Position the center crossmember over the center and rear transaxle mount studs. Start 2 nuts on the center mount.
  2.  
  3. Loosely install the 3 bolts which hold the center crossmember to the radiator support.
  4.  
  5. Loosely install the 2 front mount bolts.
  6.  
  7. Raise the main crossmember into position over the rear mounting studs.
  8.  
  9. Align all the under body bolts and bolt holes.
  10.  
  11. Install the 2 rear mount nuts loosely.
  12.  
  13. Loosely install the 8 bolts to hold the main crossmember to the underbody.
  14.  
  15. On each side, loosely install the 2 bolts holding the control arm brackets to the underbody.
  16.  
  17. Loosely install the 2 bolts holding the center crossmember to the main crossmember.
  18.  
  19. Install the exhaust hanger bracket and its 3 nuts. The crossmembers, mounts, through bolts and brackets should now all be in place and held loosely by their nuts and bolts. If any repositioning is necessary, do so now.
  20.  
  21. Tighten the components below in the order listed to the correct torque specification:
    1. Main crossmember to underbody bolts: 152 ft. lbs.
    2.  
    3. Lower control arm bolts: 94 ft. lbs.
    4.  
    5. Center crossmember to radiator support bolts: 45 ft. lbs.
    6.  
    7. Front, center and rear mount bolts: 45 ft. lbs.
    8.  
    9. Exhaust hanger bracket nuts: 9.5 ft. lbs. (115 inch lbs.)
    10.  
    11. Front mount through bolt: 64 ft. lbs.
    12.  

  22.  
  23. Install the covers on the front and center mount bolts.
  24.  
  25. Reinstall the drive axles.
  26.  
  27. Fill the transaxle with the correct amount of Dexron®II ATF. If the transaxle has been disassembled and drained, install 5.8 US qts. If the transaxle was not disassembled and still contains fluid, add 2.4 US qts. Refer to the Capacities Chart in Routine Maintenance .
  28.  
  29. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  30.  
  31. Install the splash shields below the engine. Install the left front wheel and lower the vehicle to the ground.
  32.  
  33. Remove the engine support apparatus.
  34.  
  35. Install the battery tray, battery and hold-down.
  36.  
  37. Start the engine and allow it to idle. With the wheels blocked front and rear and your foot on the brake, engage each gear and check that the transaxle engages properly. Check that the car will not roll in PARK .
  38.  
  39. Allow the engine to idle with the transaxle in PARK ; check the fluid level on the dipstick. Check all assembly points for any sign of leakage.
  40.  

1993

See Figures 1, 2 and 3

  1. Disconnect the negative (-) battery cable.
  2.  
  3. Disconnect the intake air temperature (IAT) sensor electrical connector from the IAT sensor.
  4.  
  5. Remove the air cleaner (ACL) cover and ACL filter from ACL. Loosen the ACL intake tube clamp.
  6.  
  7. Remove the 3 bolts and ACL from the vehicle.
  8.  
  9. Remove the TV cable from the throttle linkage and TV cable bracket.
  10.  
  11. Remove the 2 bolts and the left transaxle mounting bracket reinforcement from the transaxle.
  12.  
  13. Remove the 1 bolt from the left transaxle mounting bracket.
  14.  
  15. Remove 1 bolt and the ground strap from the transaxle.
  16.  
  17. Remove 1 bolt and the throttle cable guide bracket from the transaxle.
  18.  
  19. Disconnect the vehicle speed sensor (VSS) electrical connector from VSS.
  20.  
  21. Remove the 3 upper transaxle-to-engine bolts from the transaxle. Install the tool J 28467-89 along with a J 28467-A or equivalent. Raise and suitably support the vehicle.
  22.  
  23. Remove the 12 bolts and the right and left splash shields from the vehicle. Place a drain pan or suitable container underneath the transaxle fluid pan.
  24.  
  25. Remove the transaxle drain plug from the transaxle fluid pan and drain the transaxle fluid.
  26.  
  27. Remove the differential filler plug from the differential cover at the rear of the transaxle, on vehicles equipped with the A131L transaxle.
  28.  
  29. Remove the differential drain plug from the transaxle and drain the differential fluid, A131L transaxle only.
  30.  
  31. Remove the right and left drive axles from the vehicle.
  32.  
  33. Remove the 2 bolts from the exhaust pipe support.
  34.  
  35. Remove 1 nut and exhaust pipe support from the center crossmember.
  36.  
  37. Disconnect the oxygen sensor O2 electrical connector from O2 at the front exhaust pipe (California specification vehicles).
  38.  
  39. Remove the 2 bolts from the front exhaust pipe-to-three way catalytic converter (TWC) mating flange.
  40.  
  41. Remove the 2 nuts from the front exhaust pipe-to-warm up three way catalytic converter (WU-TWC) mating flange and front exhaust pipe from vehicle (California specification vehicles).
  42.  
  43. Remove the 2 nuts from the front exhaust pipe-to-exhaust manifold mating flange and front exhaust pipe from vehicle.
  44.  
  45. Remove the plastic cover from the front transaxle mounting cavity in center crossmember.
  46.  
  47. Remove the 14 bolts, 3 nuts, and the front suspension crossmember and center crossmember from the vehicle.
  48.  
  49. Remove the starter motor positive (+) terminal nut, positive(+) battery cable and the electrical connector from the starter motor.
  50.  
  51. Remove the 2 bolts and the starter motor from the transaxle.
  52.  
  53. Disconnect the park/neutral position (PNP) switch electrical connector from the PNP switch.
  54.  
  55. Disconnect the solenoid wire harness electrical connector from the solenoid wire harness (A245E).
  56.  
  57. Remove 1 nut, 1 lock washer and the shift select cable from the manual lever.
  58.  
  59. Remove 1 E-clip and the shift select cable from the shift select cable bracket at the transaxle.
  60.  

Plug the fluid cooler hoses to prevent transaxle fluid cooler leakage.

  1. Remove the 2 fluid cooler hose clamps and the fluid cooler hoses from the fluid cooler pipes at the transaxle.
  2.  
  3. Remove the flywheel cover from the engine rear end plate.
  4.  
  5. Remove 6 flywheel-to-torque converter bolts from the flywheel. Remove the drain pan from underneath the transaxle fluid pan. Support the transaxle with a suitable hydraulic jack.
  6.  
  7. Remove the 2 bolts from the left transaxle mounting bracket.
  8.  
  9. Remove the 5 lower transaxle-to-engine bolts from the transaxle.
  10.  
  11. Remove the transaxle from the engine by carefully moving the transaxle away from the engine toward the left side of the engine compartment and very slowly lowering the hydraulic jack making sure no obstructions exist.
  12.  

To install:
  1. Before installing the transaxle assembly, these steps and precautions must be followed:
    1. Apply grease around the pilot at the center of the torque converter. This will ensure ease of assembly.
    2.  
    3. Measure the distance between the outside edge of the torque converter housing and the torque converter lug. The distance should be more than 0.906-inch (23 mm). If it is less than 0.906-inch (23 mm), the torque converter is improperly installed. Remove the torque converter and properly seat it on the input shaft.
    4.  

  2.  
  3. Install the transaxle to the engine by carefully raising the transaxle using a suitable hydraulic jack making sure no obstructions exist.
  4.  
  5. Connect 5 lower transaxle-to-engine bolts into the transaxle. Tighten transaxle-to-engine bolts to 47 ft. lbs. (64 Nm).
  6.  
  7. Install 2 bolts into the left transaxle mounting bracket. Tighten the left transaxle mounting bracket bolts to 17 ft. lbs. (23 Nm). Remove the hydraulic jack from underneath the transaxle.
  8.  
  9. Install 6 flywheel-to-torque converter bolts into the flywheel. Tighten the flywheel-to-torque converter bolts to 14 ft. lbs. (19 Nm).
  10.  
  11. Install the flywheel cover into the engine rear end plate.
  12.  
  13. Connect the fluid cooler hoses to fluid cooler pipes at the transaxle; secure with two fluid cooler hose clamps.
  14.  
  15. Install shift select cable into the shift select cable bracket at the transaxle; secure with one E-clip.
  16.  
  17. Install shift select cable to manual lever and secure with 1 nut and 1 lock washer. Adjust the shift select cable.
  18.  
  19. Install the solenoid wire harness electrical connector to the solenoid wire harness.
  20.  
  21. Install PNP switch electrical connector to the PNP switch.
  22.  
  23. Install the starter motor into the transaxle and secure with 2 bolts. Tighten the starter motor bolts to 29 ft. lbs. (39 Nm).
  24.  
  25. Install the starter motor electrical connector and the positive (+) battery cable to the starter motor; secure with starter motor positive (+) terminal nut. Tighten the starter motor positive (+) terminal nut to 44 inch lbs. (5 Nm).
  26.  
  27. Install the center crossmember and the front suspension crossmember to the vehicle and secure with the 3 nuts and 14 bolts. Tighten the center crossmember and the front suspension crossmember bolts and nuts as shown:
  28.  



A bolt: 45 ft. lbs. (61 Nm)
 
B bolt: 47 ft. lbs. (64 Nm)
 
C bolt: 152 ft. lbs. (206 Nm)
 
D bolt: 152 ft. lbs. (206 Nm)
 
E nut: 42 ft. lbs. (57 Nm)
 



Click image to see an enlarged view

Fig. Fig. 3: Tighten the front suspension crossmember and center crossmember bolts and nuts to the values outlined in the text.

  1. Install the plastic cover into the front transaxle mounting cavity in the center crossmember.
  2.  
  3. Install the front exhaust pipe to the vehicle and secure with the 2 nuts at the front exhaust pipe-to-exhaust manifold mating flange. Tighten the front exhaust pipe-to-exhaust manifold nuts to 46 ft. lbs. (62 Nm).
  4.  
  5. Install the front exhaust pipe to the vehicle and secure with the 2 nuts at front exhaust pipe-to-WU-TWC mating flange (California specification vehicles). Tighten the front exhaust pipe-to-WU-TWC mating flange nuts to 46 ft. lbs. (62 Nm).
  6.  
  7. Install the 2 bolts to the front exhaust pipe-to-TWC mating flange. Tighten the front exhaust pipe-to-TWC mating flange bolts to 32 ft. lbs. (43 Nm). (California specification vehicles).
  8.  
  9. Install the O2 electrical connector to the O2 at the front exhaust pipe (California specification vehicles).
  10.  
  11. Install the exhaust pipe support to center crossmember and secure with the 1 nut. Tighten the exhaust pipe support not to 14 ft. lbs. (19 Nm).
  12.  
  13. Install the exhaust pipe support to the front exhaust pipe and secure with the 2 bolts. Tighten the exhaust pipe support bolts to 14 ft. lbs. (19 Nm)
  14.  
  15. Install the right and left drive axles into the vehicle.
  16.  
  17. Install the differential drain plug into the transaxle, on A131L transaxles only. Tighten the differential drain plug to 11 ft. lbs. (15 Nm).
  18.  


WARNING
The differential portion of the A131L 3-speed automatic transaxle is separated from the rest of the transaxle and must be drained and refilled separately. The differential portion of the A131L 3-speed automatic transaxle cannot be drained or refilled through the transaxle drain plug or fluid filler tube. If the differential portion is drained and not refilled as outlined in this procedure, damage to the differential due to lack of lubrication will result.

  1. Refill differential with approximately 1.5 qts. (1.4 liters) of Dexron®II Automatic Transmission Fluid GM P/N 1051855, or equivalent into the differential filler plug hole. Fluid level should be even with the bottom of the differential filler plug hole (A131L). Install the differential filler plug into the differential cover at the rear of the transaxle (A131L). Tighten the differential filler plug to 11 ft. lbs. (15 Nm).
  2.  
  3. Install the transaxle drain plug into the transaxle fluid pan. Tighten the transaxle drain plug to 13 ft. lbs. (17 Nm).
  4.  
  5. Install the right and left splash shields to the vehicle and secure with the 12 bolts. Tighten the splash shield bolts to 44 inch lbs. (5 Nm). Lower the vehicle. Remove the tool J 28467-A along with tool J 28467-89.
  6.  
  7. Install the 3 upper transaxle-to-engine bolts into the transaxle. Tighten the transaxle-to-engine bolts to 47 ft. lbs. (64 Nm).
  8.  
  9. Install the VSS electrical connector the VSS.
  10.  
  11. Install the TV cable guide bracket onto the transaxle and secure with the 1 bolt. Tighten the TV cable guide bracket bolt to 71 inch lbs. (8 Nm).
  12.  
  13. Install the ground strap to the transaxle and secure with the 1 bolt. Tighten the ground strap bolt to 115 inch lbs. (13 Nm).
  14.  
  15. Install the 1 bolt into the left transaxle mounting bracket. Tighten the left transaxle mounting bracket bolt to 17 ft. lbs. (23 Nm).
  16.  
  17. Install the left transaxle mounting bracket reinforcement onto the transaxle and secure with the 2 bolts. Tighten the left transaxle mounting bracket reinforcement bolts to 17 ft. lbs. (23 Nm).
  18.  
  19. Install the TV cable into TV cable bracket and throttle linkage. Adjust the TV cable as outlined earlier in this Section.
  20.  
  21. Install ACL into the vehicle and secure with the 3 bolts. Tighten the ACL bolts to 44 inch lbs. (5 Nm). Tighten the ACL intake tube clamp.
  22.  
  23. Install the ACL filter and the ACL cover onto the ACL.
  24.  
  25. Install the IAT sensor electrical connector to IAT sensor.
  26.  
  27. Install the negative (-) battery cable. Tighten the negative battery cable-to-negative battery terminal retainer to 11 ft. lbs. (15 Nm).
  28.  
  29. Refill the transaxle as necessary. Please refer to Capacities Chart in Routine Maintenance .
  30.  

 
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