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1991 Saturn SL Series CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Saturn REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1991 Saturn SL Series AUTOMOBILES
A/C & Cooling System Maintenance -> General Motors Corp. -> 1991-2002 Saturn
Vehicle: 1991 Saturn SL Series 1.9 L4 GAS
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BRAKE SERVICE PROCEDURES FOR 1991 Saturn SL Series AUTOMOBILES
SATURN -> Disc Brakes -> REAR DISC BRAKE -> Assemble -> BRAKE PADS, REPLACE -> CALIPER SERVICE -> CALIPER, REPLACE -> Disassemble
Vehicle: 1991 Saturn SL Series 1.9 L4 GAS
BRAKE PADS, REPLACE
- Raise and support vehicle.
- Remove wheel assemblies.
- Remove caliper lock pin and guide pin.
- Remove caliper from support, then using suitable wire hang aside.
- Remove brake pads from caliper support.
- Remove two pad clips from caliper support.
- Reverse procedure to install.
CALIPER, REPLACE
- Raise and support vehicle.
- Remove wheel assemblies.
- Disconnect caliper brake fluid lines and plug opening.
- Slip parking brake cable end from brake lever, then using cable release tool No. SA9151BR or equivalent, remove cable outer housing.
- Remove caliper lock pin and guide pin.
- Remove calipe...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Saturn SL Series AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Filter Scheduled Maintenance -> 1991-06 Saturn -> Normal Service -> Severe Service
Vehicle: 1991 Saturn SL Series 1.9 L4 GAS
Normal Service
Replace every 100,0...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Saturn SL Series AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1991 Saturn SL Series 1.9 L4 GAS
- Depress brake pedal and loosen drive axle nut.
- Raise and support vehicle, then remove front wheel and tire assembly and front inner splash shield. If left drive axle or intermediate shaft is being removed, drain fluid from transaxle.
- Remove drive axle nut and washer.
- Remove and discard lower control arm to steering knuckle cotter pin.
- Loosen lower control arm to steering knuckle castle nut to point where top of castle nut is even with top of ball stud. Do not remove castle nut at this time.
- Separate lower control arm from steering knuckle, using removal tool No. SA9132S or equ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Saturn SL Series AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Saturn SL Series 1.9 L4 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Remove passenger side tire and wheel.
- Remove splash guards.
- Working through passenger side wheel well, release tension on drive belt and remove drive belt.
- Disconnect electrical conn...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Saturn SL Series AUTOMOBILES
General Motors Corp./Saturn Cars -> Active Handling System Warning Lamp ->
Vehicle: 1991 Saturn SL Series 1.9 L4 GAS
This lamp should light for a approximately 6-8 seconds when the ignition is turned on as a bulb check. The lamp will also come on as the system is...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Saturn SL Series AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1991 Saturn SL Series 1.9 L4 GAS
Lower
- Drain coolant into a suitable container.
- Loosen hose clamp connecting hose to radiator.
- Loosen hose clamp connecting hose to water pump inlet.
- Remove hose from vehicle.
- Reverse procedure t...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Saturn SL Series AUTOMOBILES
Serpentine Drive Belt, Replace -> Installation -> Removal
Vehicle: 1991 Saturn SL Series 1.9 L4 GAS
Removal
- Depress tensioner arm, using suitable 14mm or 9/16 inch wrench.
- Remove belt from A/C compressor and idler pulley, then remove belt.
Installation
- Route belt over a...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Saturn SL Series AUTOMOBILES
Component location diagrams for most 1991 Saturn SL Series cars and light trucks sold in the U.S. from 1990+.
Chime/Delayed Dome Diagram for 1991 Saturn SL Series 1.9 L4 GAS Components on diagram: |
Engine Grounds Diagram for 1991 Saturn SL Series 1.9 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1991 Saturn SL Series AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Saturn SL Series cars and light trucks sold in the U.S.
1991 Saturn SL Series 1.9 L4 GAS Wiring Diagram Components on diagram: |
1991 Saturn SL Series 1.9 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Saturn SL Series AUTOMOBILES
OEM TSB listings for most 1991 Saturn SL Series cars and light trucks sold in the U.S. from 1985+.
Document: Car and Truck Fix It Right the First Time Issues Vehicle: 1991 Saturn SL Series 1.9 L4 GAS Auto Systems: |
Document: GM TIRE WARRANTY PROGRAM CLAIMS GOODWILL GUIDELINES - REVISED Vehicle: 1991 Saturn SL Series 1.9 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Saturn SL Series AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Saturn SL Series cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 Saturn SL Series cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 Saturn SL Series cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 Saturn SL Series cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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