Engine Front Cover Replacement DOHC

Tools Required

• SA9103E Regulator Valve Remover/Replacer
• SA9104E Front Crank Seal Replacer

1. Clean the front cover, cylinder block and oil pan mating surfaces:

Notice

If excessive RTV is applied, or oil builds up in the blind holes, the casting will crack when the bolts are installed. Make sure all oil gallery openings and the oil pan are covered with a shop towel to prevent debris entry.

1. RTV is removed from aluminum surfaces using scraper, plastic or wood, Scotch-Brite® Pads, and disk (3M® Clean-N Strip 2 in D x 1/2 in W x 1/4 in center hole).
2. The front cover, cylinder head and block bolt holes must be cleaned with a 3/16 in drill and tap handle. The oil drain back hole must also be free of RTV. The front cover non tapped holes can be cleaned with 3/8 in drill.

Important

Do not use petroleum cleaners such as mineral spirits, they leave a film onto which RTV will not stick.

3. After all RTV is removed, clean the surfaces with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol.





Important

If removed, the oil pump must be packed with petroleum jelly for printing.

2. Install the oil pressure regulator and pump cover if removed. Install the regulator using the SA9103E and a hammer. The pump should be installed with the chamfer toward the front oil seal.
Tighten

Tighten the oil pump cover-to-front cover to 11 N·m (8 lb ft).

3. If the front seal was removed, use the SA9104E service tool to install a new seal. Never tap on the seal or seal installer with a hammer.
4. Install the new oil pressure and suction seals into their respective cavities in the cylinder block.

Important

The front cover, oil seal drain back hole, and passage way must be kept free of RTV.

Important

Extra RTV is required at oil pan, cylinder head to block, cylinder head and cam cover T-joints to make sure gaps are filled.

5. Apply a 4 mm (0.158 in) bead, refer to the RTV Section on the front of the oil pan and a 2 mm (0.079 in) bead on the front cover. Apply RTV around the front cover top, center bolt hole. Install the cover immediately.




6. Install the front crank seal using the SA9104E . The  tool aligns the generator pump during front cover installation.




7. Install the front cover assembly fasteners.
Tighten
• Tighten the front cover perimeter bolts to 30 N·m (22 lb ft).
• Tighten the front cover lower center bolt (number 14) to 10 N·m (89 lb in).
8. Install the 4 oil pan fasteners.
Tighten

Tighten the oil pan-to-block 9 N·m (80 lb in).

Notice

After the front cover is installed, 6-12 squirts of oil can be pumped through the front oil seal drain back hole to make sure it is not plugged to prevent front seal damage.









Important

Inspect the cam cover isolators for cracks. Replace the isolators if deterioration exists.

9. Apply RTV across the cylinder head and front cover "T" joints, refer to "RTV" procedures in General Information. The cam cover gasket can be reused if not damaged.




10. Install the cam cover assembly and tighten the fasteners uniformly.
Tighten

Tighten the camshaft cover-to-head (LL0) to 10 N·m (89 lb in).





11. Install water pump pulley, if removed.
Tighten

Tighten the water pump pulley-to-water pump hub 25 N·m (19 lb ft).

Important

Install a thin film of RTV sealant Saturn P/N 21006236 between the damper/pulley assembly flange and washer only. The washer and bolt head flange are designed to prevent oil leakage and do not require RTV sealant.

Important

Hold the damper with a strap wrench or use a 3/4 in square x 12 in long piece of wood wedged between the damper spoke and rear, lower side of cover when torquing the bolt.

12. Install the crankshaft vibration damper/pulley assembly and retaining bolt.
Tighten

Tighten the crankshaft vibration damper/pulley-to-crankshaft to 215 N·m (159 lb ft).

13. Install the intake upper manifold support brace bolt located next to generator.
Tighten

Tighten the intake manifold brace-to-block (LL0) to 10 N·m (89 lb in).

14. Drain the engine oil and change the filter. Install the drain plug.
Tighten

Tighten the oil pan drain plug to 37 N·m (27 lb ft).

15. Verify the gap on all spark plugs.
Install the spark plugs. Tighten

Tighten the spark plug-to-head to 27 N·m (20 lb ft).

Important

Install the accessory drive belt idler pulley, if removed.

16. Install the belt tensioner.
Tighten
• Tighten the belt tensioner-to-block to 30 N·m (22 lb ft).
• Tighten the belt tensioner-to-front cover to 27 N·m (20 lb ft).
17. Install generator attachment bolts/nut (both), if removed.
Tighten

Tighten the generator bolts to 32 N·m (24 lb ft).

18. Install power steering pump assembly and brackets.
Tighten
• Tighten the power steering pump bracket-to-block to 30 N·m (22 lb ft).
• Tighten the power steering pump brace-to-block to 30 N·m (22 lb ft).
19. Install A/C compressor and bolts.
Tighten
• Tighten the A/C compressor brackets-to-head/block to 25 N·m (19 lb ft).
• Tighten the A/C compressor-to-front bracket to 54 N·m (40 lb ft).
• Tighten the A/C compressor-to-rear bracket to 30 N·m (22 lb ft).




20. Install the accessory drive belt. Ensure that the belt is properly aligned on the pulleys.

Notice

To prevent engine front cover and mount damage, the three engine mount to engine front cover nuts must be tightened down uniformly.

21. Install the 2 mount to midrail bracket nuts first. Next, install the 3 front upper mount to engine front cover nuts. Remove the block of wood from under the torque strut after the upper mount assembly is installed.
Tighten
• Tighten the upper engine mount-to-front cover to 50 N·m (37 lb ft).
• Tighten the upper engine mount-to-front rail bracket to 50 N·m (37 lb ft).
22. Install splash shield and wheel.
Tighten

Tighten the wheel nuts to 140 N·m (103 lb ft).

23. Install the following sensors and components:
• The oxygen sensor Tighten

  Tighten the oxygen sensor to 45 N·m (33 lb ft).

• The engine coolant temperature (ECT) sensor Tighten

  Tighten the coolant temperature sensor to 8 N·m (71 lb in).

• Throttle body assembly, if removed Tighten

  Tighten the throttle body-to-air intake manifold (LL0) to 12 N·m (9 lb ft).

• The starter motor to block, if removed Tighten

  Tighten the starter motor-to-block to 37 N·m (27 lb ft).

• The starter support bracket to axle shaft, if removed Tighten

  Tighten the starter support bracket-to axle shaft bracket to 30 N·m (22 lb ft).

• The EVAP canister purge Tighten

  Tighten the canister purge solenoid-to-block to 22 N·m (16 lb ft).

• The EGR valve Tighten

  Tighten the EGR valve-to-head 25 N·m (19 lb ft).

24. Install the following sensors and electrical harness connectors and vacuum hoses.
1. Electrical Connectors:
• Grounds, if disconnected
• Generator
• Oxygen sensor
• Starter
• Coolant temperature sensor
• A/C compressor
• Idle air control (IAC)
• Throttle position (TP) sensor
• EGR valve
• Injectors
2. Vacuum Hoses:
• EVAP canister purge
• Throttle body
• PCV
• Fresh air
• Brake booster




25. Install the accelerator cable to the bracket and attach the throttle cable. Ensure the throttle cable is properly routed and not binding.
26. Install the coolant hoses.
• Upper radiator
• Heater
• Deareation hose at rear side of intake manifold

Notice

Replace plastic fuel retainer whenever the fuel supply is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

Important

The service retainers are different in color from the original equipment retainers. The service fuel feed line retainers are clear in color.

27. Lubricate with clean engine oil the male fuel feed line. Attach the fuel feed line and pull back to confirm engagement.
28. Install the fuel line clip to the intake manifold stud.
Tighten

Tighten the fuel line retainer clip to 4 N·m (35 lb in).

29. Install the intake manifold bracket and attach the fuel supply line.
Tighten
• Tighten the support bracket-to-intake manifold (LL0) to 10 N·m (89 lb in).
• Tighten the support bracket-to-intermediate shaft support bracket (LL0) to 30 N·m (22 lb ft).
30. Install the air intake resonator, tube, filter cover and clamps. Refer to Induction section of this service manual.
31. Connect the battery cables, positive cable first.
Tighten

Tighten the battery terminal bolts to 17 N·m (13 lb ft).

32. Install the oil pan drain plug and fill engine with new oil.
Tighten

Tighten the oil pan drain plug to 37 N·m (27 lb ft).

33. Install the cylinder block coolant drain plugs and close the radiator drain.
Tighten

Tighten the coolant drain-to-plug/block 30 N·m (22 lb ft).

Important

The vehicle must be level when filling with coolant.

34. Fill with coolant. Use only DEX-COOL™ ethylene glycol-based antifreeze.
35. Prime the fuel system.
1. Cycle the ignition on for 5 seconds and then off for 10 seconds.
2. Repeat step 31.1 twice.
3. Crank engine until it start, maximum starter motor cranking time is 20 seconds.
36. Start the engine and check for leaks.

Important

Allow the engine to idle for 3-5 minutes. If lifters are noisy or cylinders are misfiring, warm the engine up at a low RPM, less than 2,000. After the coolant temperature has reached approximately 85°C (185°F), cycle the engine RPM from idle to 3,000 for approximately 10 minutes or drive the vehicle 5 miles to purge the air. If the air cannot be purged, the faulty lifters will have to be replaced.

Lash adjusters that are pumped up may cause PCM misfire codes to set. Continue to operate the engine until the lash adjusters bleed down. Using the scan tool, clear codes and malfunction history.

37. Perform a 3 mile road test.
38. Fill the cooling system surge tank to the FULL COLD line and check for leaks after the engine has been tested.