Saturn

How to Replace a Windshield Wiper Motor and Transmission Linkage Assembly

This set of repair instructions apply to-

2005-2009 Pontiac G6
2008-2012 Chevy Malibu
2007-2009 Saturn Aura

Often referred to a Wiper System Module, this is made up of  a wiper motor and the mechanical linkage that actuates the wiper blades.  After several years of use or from excessive
conditions like snow, this linkage can break and cause the wiper blades to move sporadically or not at all.

Windshield Wiper Motor (Part #: 22711011) & Transmission Linkage Assembly (Part #: 22711010)

Removal
1.) Ensure that the wipers are set to the ‘PARK’ position


2.) Open hood
3.) Remove wiper arm nut finish cap
4.) Remove the wiper arm nut
5.) To remove the wiper arm requires a special tool.
** Removing the wiper arm without a removal tool. Fold wiper arm to the service position (facing upward) gentle rock the arm on pivot shaft to remove


6.) Remove the air inlet grille panel and hood seal. Fasteners are most often push-pin style.  But, some models do use small trim bolts.
7.) Remove the bolts attaching the wiper module to the plenum


8.) Carefully lift the wiper module out of the plenum
9.) Disconnect the electrical connector from the wiper motor and the clip retaining the electrical harness to the wiper motor
10.) Remove the wiper module assembly from the vehicle

Reverse removal procedure for installation.
*When installing the wiper arms, align the wiper arm onto the wiper module pivot shaft with wiper blade to the wiper dots/stops on the windshield.
When job is complete inspect for proper operation.

Torque Specs
Wiper Arm Nuts 25 lb ft
Wiper Module Bolts 89 lb in


Does your ECOTEC engine have an oil leak?

Vehicles with the Ecotec 2.0L, 2.2L or 2.4L engine, may have a undersized oil drain plug thread insert that was installed incorrectly or has moved during the re-installation of drain plug well doing an oil change.  Once the insert has moved, the threads have a much higher chance of stripping. Stripped drain plug threads can cause the drain plug to loosen or not tighten, resulting in an oil leak.

Another common occurrence of an oil leak comes from the vehicle bottoming out,  hitting the oil pan and causing a crack.  This condition is most common in the Chevy HHR.

Click here for APDTY Ecotec Oil Pan Page

Oil Pan Replacement

1.) Remove the oil level indicator and tube.
2.) Raise and support the vehicle.
3.) Place a drain pan under the oil pan drain plug.
4.) Remove the oil pan drain plug.
5.) Drain oil.
6.) Re-install the oil pan drain plug.
7.) Remove the engine drive belt.
8.) Remove the lower air conditioning (A/C) compressor bolt.
9.) If the vehicle is equipped with a manual transaxle, remove the 2 lower transaxle bolts.
10.) If the vehicle is equipped with a automatic transaxle, remove the 4 lower transaxle bolts.
11.)  Remove the oil pan bolts.
12.) Remove the oil pan.
13.)  Clean all gasket sealing surfaces and ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris.
14.) Apply a 2 mm bead of sealant (1) around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm bead is not required.
15.) Install the oil pan, tighten oil pan bolts in sequence shown
16.) Reverse removal procedure to install

Tighten the oil pan bolts in the sequence shown,  Tighten the bolts to 25 N.m (18 lb ft).
*If the vehicle is equipped with a automatic transaxle,  the 4 lower transaxle bolts. Tighten the bolts to 75 N.m (55 lb ft).
*If the vehicle is equipped with a manual transaxle, remove the 2 lower transaxle bolts. Tighten the bolts to 75 N.m (55 lb ft)
*Install the lower A/C compressor bolt. Tighten the bolt to 20 N.m (15 lb ft).


Acura and Honda vehicles with V6 engines, having problems with EGR trouble codes PO401 or P1491 and/or engine pinging.

Acura and Honda’s with V6 engines, with EGR trouble codes and/or engine pinging. Check engine light on with DTC’s PO401 (insufficient EGR flow) or P1491 (insufficient EGR lift), This problem is due to the EGR port being clogged causing the failure. Honda has issued a TSB (Technical Service Bulletins) TSB-99-085 for the corrective action for cleaning the EGR port, and installing new EGR pipe kit. TechSmart™ has also released a similar solution for unclogging and replacing the EGR port tube.

The TechSmart™ EGR fix consist of a tool kit B22001 a coated, stepped drill bit and a punch tool. The repair kit F23001, includes a new EGR tube, throttle body and EGR valve gasket.

Corrective Action for Cleaning the EGR port, and installing the EGR Pipe Kit
Applies For:
1998-00 Accords V6 – ALL
2001 Accord V6 – 4-door from VIN 1 HGCG 1…1 A000001 thru  1 HGCG1…1 A058564
2001 Accord V6 – 2-door from VIN 1 HGCG2…1 AO00001 thru   t HGCG2…1A023388

BACKGROUND: In some areas of the U.S., certain basic chemical properties of gasoline (regardless of brand) may cause the intake manifold EGR port to clog or the EGR valve to fail. If this happens, the MIL comes on with a DTC P0401 (insufficient EGR flow) or P1491 (insufficient EGR lift) stored.

REPAIR PROCEDURE:
1. Remove the throttle body cover, intake manifold covers, ignition wire holder, and ignition wire cover.

2. Disconnect the brake booster vacuum hose and the vacuum hose from the intake manifold
3. Remove the throttle body from the intake manifold (two nuts and two bolts). Leave all hoses, cables, and electrical connectors connected to the throttle body. Discard the throttle body gasket.


4. Remove the PCV valve from the cylinder head cover. Remove the intake manifold (three nuts and six bolts).
5. Remove the intake manifold chamber, IAT sensor, boost plate, and PCV hose from the intake manifold.


6. Cover the six ports on the bottom of the manifold with duct tape.


7. Use a 8-mm drill bit and carburetor cleaner to clean the EGR port in the intake manifold. Turn the drill bit only by hand. Do not use a power drill.
8. Put the special drill bit from the EGR pipe installation kit in your power drill. Coat the drill bit completely with clean engine oil. NOTE: The oil coating is critical to drilling the hole accurately, and it contributes to drill bit life.
9. Insert the guide part of the drill bit into the EGR port. Make sure it is inserted fully. Then drill out the EGR port using steady pressure on the drill Make sure the port is drilled through completely.


10. Clean up the aluminum Chips from drilling, then remove the duct tape.
11. Put the Manifold in a parts washer (solvent or soap and water) and clean it thoroughly.
• Flush out the EGR port for 20 seconds.
• Flush out the manifold from the throttle body opening. Run cleaner down each side for 20 seconds.
• Flush each intake runner for 10 seconds. Start at the throttle body end and work towards the back.
• Turn the manifold so the throttle body opening is facing down. Flush each main runner for 20 seconds.
• Dry the manifold with compressed air and clean shop towels.


12. Place the EGR pipe from the kit into the EGR port.


13. Use the installation tool and a small hammer to drive the EGR pipe into the port until it is flush with the port. Make sure the pipe will not contact the gasket after installation.


14. Install the intake manifold chamber; torque the nuts and bolts to 12 N•m (8.7 lb-ft). Install the IAT sensor; torque it to 18 N•m (13 lb-ft). Install the boost plate; torque the bolts to 12 N•m (8.7 lb-ft). Install the PCV hose.
15. Inspect the EGR port in the front of the injector base on the engine. If it is partially or fully clogged, clean the port.
16. Disconnect the 6P connector from the EGR valve. Remove the
EGR valve.


17. Install the new EGR valve with newly supplied gasket; Torque the mounting nuts to 22 N•m (16 Ib-ft). Reconnect the 6P connector.
18. Install the intake manifold with the original gasket. Torque the mounting nuts and bolts to 22 N•m (18 lb-ft) sequentially in two or three steps. Route the PCV hose so it is not pinched under the intake manifold.


19. Install the PCV valve in the cylinder head cover.
20. Install the throttle body with a new gasket. Torque the mounting nuts and baits to 22 N•m (18 Ib-ft).
21. Reinstall the brake booster vacuum hose, vacuum hose, ignition wire holder, and all of the covers.
22. Connect the PGM Tester (loaded with SN200 or later software). Clear any DTCs.
23. Use the PGM Tester to override two-trip error detection.
• From the PGM tester menu, select 1. Honda Systems.
• Then select 2. SCS.
24. Test-drive the vehicle to make sure no new OTCs are set.

 

B22001 Tool kit
2001-2003,1997-1999 Acura CL
2003-2009 Acura MDX
1999-2008 Acura TL
1998-2007 Honda Accord
1999-2007 Honda Odyssey
2003-2008 Honda Pilot
2006-2008 Honda Ridgeline
2004-2007 Saturn Vue

F23001 Repair Kit
1999 Acura TL
1998-2001 Honda Accord
2006-2008 Honda Ridgeline
2004-2007 Saturn Vue


What is a Electronic Throttle Body or commonly referred to as Throttle-By-Wire, Fly-By-Wire, Drive-By-Wire (DBW) or Throttle Actuator Control (TAC)?

Electronic Throttle Bodies? Where’s the throttle cable? As you may already know opening the hood in a modern car reveals systems alot different than that of years past. As engine life has been extended and engine controls have become more complex, longer-life and higher-reliability electronic components are required. These advances in electronic componets aid the Power Control Module (PCM) to stay within the programed perimeters for the best performance and emission regulations.  One of these components being the Electronic Throttle Control (ETC) system often referred to as throttle-by-wire, fly-by-wire, drive-by-wire (DBW) or throttle actuator control (TAC). Using a array of sensors the on-board computer system measures throttle demand, then sends out a signal (electronic command) to the electronic throttle body. This computer command is to operate a servo motor controlling the throttle plate/blade or butterfly.

What seems to be the failure of the Electronic Throttle Body is the plastic gear drive. A common problem of the throttle body bore has been a build up of gases from the EGR and PVC systems, combined with heat causes a formation of gummy residue. This gummy residue often restricts airflow causing poor or hunting idle and even stalling conditions. This residue can become so built up that it causes the throttle body plate/blade to stick, striping out the gear drive in the throttle body.

TechSmart™ has a complete line of New Electronic Throttle Bodies, offering a cost effective solution for repairing  failed electronic throttle bodies for many makes and models.

S20001
2010-2009 Ford Light Truck Expedition
2010-2009 Ford Light Truck F Series Fullsize Pickup
2010-2009 Lincoln Navigator

S20002
2007-2006 Cadillac CTS
2008-2006 Chevrolet Corvette
2009-2008 Pontiac G8
2006-2005 Pontiac GTO

S20003
2007-2006 Buick Rendezvous
2006-2005 Buick Terraza
2006-2005 Chevrolet Malibu / Malibu Maxx
2006-2005 Chevrolet Light Truck Equinox
2006-2005 Chevrolet Light Truck Uplander
2006-2005 Pontiac G6
2006-2005 Pontiac Montana
2006-2005 Saturn Relay

S20004
2008-2006 Buick LaCrosse
2006 Buick Rendezvous
2007-2006 Cadillac CTS
2006 Cadillac SRX
2007-2006 Cadillac STS

S20005
2006-2004 Cadillac SRX
2009-2006 Cadillac XLR
2006-2005 Pontiac Torrent

S20006
2004 Buick Rainier,
2006-2003 Cadillac Escalade,
2006-2003 Chevrolet Light Truck Fullsize Pickup
2007-2004 Chevrolet Light Truck G Series Fullsize Van / Express
2006-2003 Chevrolet Light Truck Suburban / Fullsize Blazer / Tahoe
2004-2003 Chevrolet Light Truck Trailblazer
2004-2003 GMC Light Truck Envoy,
2006-2003 GMC Light Truck Fullsize Pickup
2007-2004 GMC Light Truck G Series Fullsize Van / Savana
2006-2003 GMC Light Truck Suburban / Fullsize Jimmy / Yukon
2007-2005 Hummer H2

S20007
2004-2003 Oldsmobile Bravada
2007 Chevrolet Light Truck Colorado
2007 GMC Light Truck Canyon
2007 Hummer H3
2007-2003 Buick Rainier
2007-2003 Chevrolet Light Truck Trailblazer
2007-2003 GMC Light Truck Envoy
07-05 Pontiac Grand Prix
2007-2005 Saab 9-7
2007-2006 Chevrolet Impala

S20009
2007 Saturn Aura
2009 Saturn Vue
2009,2010 Buick Lucerne
2009,2010 Chevrolet Impala
2009-2006 Chevrolet Light Truck Uplander
2009-2006 Pontiac Montana
2009-2006,2010 Chevrolet Malibu / Malibu Maxx
2009-2006,2010 Pontiac G6
2009-2007 Chevrolet Light Truck Equinox
2009-2007 Pontiac Torrent

S20010
2001-1999 Cadillac Catera
2004-2003 Cadillac CTS

S20011
2002 Chevrolet Light Truck Trailblazer
2002 GMC Light Truck Envoy
2002 Oldsmobile Bravada

S20012
2008-2005 Pontiac Grand Prix
2008-2006 Buick Lucerne
2009-2005 Buick LaCrosse

S20013
2007 Chevrolet Light Truck Colorado
2007 GMC Light Truck Canyon
2007-2004 Saturn Ion
2007-2005 Chevrolet Cobalt

S20014
2006-2003 Chevrolet Light Truck Suburban / Fullsize Blazer / Tahoe
2006-2003 GMC Light Truck Suburban / Fullsize Jimmy / Yukon
2007-2003 Chevrolet Light Truck Fullsize Pickup
2007-2003 GMC Light Truck Fullsize Pickup

S20015
2009-2008,2010 Chevrolet Light Truck HHR
2009-2008,2010 Chevrolet Malibu / Malibu Maxx
2010 Chevrolet Light Truck Equinox
2010 GMC Light Truck Terrain

S20016
2008-2007 Chevrolet Malibu / Malibu Maxx
2009-2007 Pontiac G5
2009-2007,2010 Chevrolet Cobalt
2009-2007,2010 Chevrolet Light Truck HHR

S20017
2009-2007 Saturn Outlook
2009-2007 Saturn Vue
2009-2007 Suzuki XL-7
2009-2007,2010 GMC Light Truck Acadia
2009-2008 Chevrolet Light Truck Equinox
2009-2008 Pontiac Torrent
2009-2008,2010 Buick Enclave
2010 Buick LaCrosse

S20018
2009-2007,2010 Cadillac SRX
2009-2008,2010 Cadillac CTS
2009-2008,2010 Cadillac STS
2010 Buick LaCrosse
2010 Chevrolet Camaro
2010 Chevrolet Light Truck Equinox
2010 GMC Light Truck Terrain

S20019
2009 Chevrolet Light Truck Avalanche
2009 Chevrolet Light Truck Suburban / Fullsize Blazer / Tahoe
2009 GMC Light Truck G Series Fullsize Van / Savana
2009 GMC Light Truck Suburban / Fullsize Jimmy / Yukon
2009 Hummer H2
2009-2010 Cadillac Escalade
2009-2010 Chevrolet Corvette
2009-2010 Chevrolet Light Truck Colorado
2009-2010 Chevrolet Light Truck Fullsize Pickup
2009-2010 Chevrolet Light Truck G Series Fullsize Van / Express
2009-2010 GMC Light Truck Canyon
2009-2010 GMC Light Truck Fullsize Pickup

S20020
2009-2010 Ford Crown Victoria
2009-2010 Ford Light Truck E Series Fullsize Van
2009-2010 Ford Mustang
2009-2010 Lincoln Town Car
2009-2010 Mercury Grand Marquis

S20021
2009-2010 Ford Light Truck E Series Fullsize Van
2009-2008 Ford Mustang

S20022
2008-2006 Ford Light Truck Explorer / Sport / Sport Trac
2008-2006 Mercury Mountaineer

S20023
2005-2004 Ford Light Truck Explorer / Sport / Sport Trac
2005-2004 Mercury Mountaineer

S20024
2006-2003 Chevrolet Light Truck G Series Fullsize Van / Express
2006-2003 GMC Light Truck G Series Fullsize Van / Savana

S20025
2007-2005 Ford Five Hundred,
2007-2005 Ford Light Truck Freestyle
2007-2005 Mercury Montego

S20026
2009-2006 Ford Fusion
2009-2006 Mercury Milan

S20027
2010 Ford Light Truck Transit Connect

S20028
2006 Lincoln Zephyr
2009-2006 Ford Fusion
2009-2006 Mercury Milan

S20030
2002-2001 Chevrolet Light Truck Fullsize Pickup
2002-2001 Chevrolet Light Truck G Series Fullsize Van / Express
2002-2001 GMC Light Truck Fullsize Pickup
2002-2001 GMC Light Truck G Series Fullsize Van / Savana
1999-1998 Chevrolet Light Truck P Series Van
1999-1998 GMCLight Truck P Series Van

S20031
2004-2000 Chevrolet Corvette
2005-2004 Cadillac CTS

S20032
2002 Cadillac Escalade
2002 Chevrolet Light Truck Avalanche
2002-2000 Chevrolet Light Truck Fullsize Pickup
2002-2000 GMC Light Truck Fullsize Pickup

S20034
2008-2005 Pontiac Vibe

S20035
2004 Pontiac Grand Prix

S20036
2002-1999 Chevrolet Camaro
2002-1999 Pontiac Firebird

S20038
2009-2005,2010 Ford Mustang


Saturn Ion Windshield Wiper Linkage / Wiper Transmission Repair / How to replace Broken Saturn Ion Wiper Transmission

It has become apparent to us recently that the Saturn Ion has a rather large engineering flaw. The critically important Windshield Wiper Transmission (The linkage assembly which connects the wiper motor to the wiper blade arms) has a flaw which in my opinion should have never been allowed to happen in the first place. One of the hinges which allows the wipers to pivot is made of PLASTIC! Over time, this plastic hinge becomes brittle and will eventually snap, causing failure of the wiper blades. If your wipers fail at the wrong time, this could lead to a serious safety situation. Imagine driving down the interstate at 60+ MPH in a heavy rainstorm, and suddenly your wipers just stop working.

In my opinion, this is a serious engineering blunder. I can only assume that the intentions of making this very important linkage hinge out of plastic was to save a couple dollars on the assembly line. But is a couple dollars worth risking the safety drivers? Luckily, we at APDTY have a solution. We carry a replacement wiper transmission which has METAL hinges, like they should have been from the factory. This replacement part has a lifetime warranty and is guaranteed to never fail on you. The replacement of this part is not extremely difficult and is achievable by almost anyone with some basic mechanical skill.

Here is a shot of the upgraded metal hinge:

upgraded metal saturn ion pivot

The basic steps are outlined below:

1) Remove the Windshield Wiper Arm Nut Covers.

2) Remove the Windshield Wiper arm Nut.

Saturn_Ion_Wiper_nut

3) Remove the wiper arms, If the arms do not come off easy there is a specialty tool available designed to pull the wiper arm off.

4)  Remove the Air inlet grille panel (Cowl Panel) by removing the push-pin fasteners and then lifting up and disconnecting the wiper fluid hose.

Saturn_Ion_Wiper_Cowl_Panel_removal

5)  Disconnect the wiring connector from the windshield wiper motor.

6) Remove the bolts that attach the whole wiper transmission/motor assembly to the car. Remove the whole assembly (Wiper Motor and Transmission Linkage) From the vehicle.

7)  Remove the Wiper Motor Crank Arm Nut. (The nut which comes out of the center of the wiper motor) and remove the crank arm from the motor.

8 ) Remove the bolts which attach the wiper motor to the transmission/linkage assembly and remove wiper motor from the assembly.

9) Install the wiper motor onto the new transmission/linkage assembly. Install the crank-arm and crank-arm nut.

10) Reverse removal instructions to install the assembly and cowl panel back into the vehicle.

11) Reinstall Wiper blade arms, be sure that the wiper motor is in full park position (where they sit when the wiper switch is off), align the wiper arms and tighten the wiper arm retaining nut.

Written By Joe Stepnicka


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