TommyTwinCams
Track Warrior
I mentioned that I needed to replaced the transmission on my Saturn due to not having fifth gear and that I was upgrading to a SPEC stage 1 performance clutch kit while I was at it. I decided to make a how to on doing it since the engine and transmission combo is popular not just in America, but in Europe and Australia as well.
I'll be updating this in increments as I don't have much time to work on it at school.
Notes: I have access to a hydraulic lift and professional tools. Not everyone is so lucky. I'm also replacing the transmission, not JUST doing the clutch, but the tranny has to come out anyways so the procedure should be the same
Car used:
2004 Saturn Ion Level 2 Quad Coupe
Engine: L61 2.2L DOHC 16 valve Ecotec 4 cylinder (AKA the Z22SE in the UK and Europe, C22SEL in Australia)
Transmission: Getrag F23 5 speed Manual (RPO code M86)
Platform: GM Delta platform (shared with Vauxhall/Opel/Holden Astra, Pontiac G5/Pursuit, Chevrolet Cobalt, and Chevrolet HHR)
Clutch Kit: 2004 Saturn Ion 2.2L SPEC Stage 1 clutch kit
Part Number: SR981
The car:
BEGIN!
1: Begin by removing the underhood Fuse box cover. It should just come off with a bit of wiggling
2: Remove the auxiliary positive battery Terminal and disconnect the 2 wires it holds on. Size should be a 10 MM socket
3: Now disconnect the negative battery cable from the battery itself. On my car, the battery is located in the trunk. No photo. Should be an 8 or 10mm bolt
4: Now the ECM and fuse box are held in by the same bracket. This bracket needs to be unbolted so you can move it around. It will not come out without the entire wiring harness to my knowledge. This bracket is called the "Junction Bracket" by my books. There are 2 nuts (one hidden by the 2 wires we just moved in step 2) and a bolt. The nuts are 10 MM and the bolt is 13 MM.
I'll be updating this in increments as I don't have much time to work on it at school.
Notes: I have access to a hydraulic lift and professional tools. Not everyone is so lucky. I'm also replacing the transmission, not JUST doing the clutch, but the tranny has to come out anyways so the procedure should be the same
Car used:
2004 Saturn Ion Level 2 Quad Coupe
Engine: L61 2.2L DOHC 16 valve Ecotec 4 cylinder (AKA the Z22SE in the UK and Europe, C22SEL in Australia)
Transmission: Getrag F23 5 speed Manual (RPO code M86)
Platform: GM Delta platform (shared with Vauxhall/Opel/Holden Astra, Pontiac G5/Pursuit, Chevrolet Cobalt, and Chevrolet HHR)
Clutch Kit: 2004 Saturn Ion 2.2L SPEC Stage 1 clutch kit
Part Number: SR981
The car:
BEGIN!
1: Begin by removing the underhood Fuse box cover. It should just come off with a bit of wiggling
2: Remove the auxiliary positive battery Terminal and disconnect the 2 wires it holds on. Size should be a 10 MM socket
3: Now disconnect the negative battery cable from the battery itself. On my car, the battery is located in the trunk. No photo. Should be an 8 or 10mm bolt
4: Now the ECM and fuse box are held in by the same bracket. This bracket needs to be unbolted so you can move it around. It will not come out without the entire wiring harness to my knowledge. This bracket is called the "Junction Bracket" by my books. There are 2 nuts (one hidden by the 2 wires we just moved in step 2) and a bolt. The nuts are 10 MM and the bolt is 13 MM.
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