RTV Sealant and Components Replacement

How to replace 96-98 DOHC plastic valve cover with 93-95 aluminum by SATURNFAN Saturninin

Tools Required

• SA9123E Gasket Seal Cutter
• SA9123E Rear Crank Seal Replacer

Removal Procedure

Important

The following removal and installation procedures are general. Refer to the specific component section for detailed information, including torque specifications.

Room temperature vulcanize (RTV) sealant is used in 6 locations on the engine as a gasket or sealant:

• The oil pan
• The front cover
• The rear crankshaft seal carrier
• The front cover, cylinder head, cam cover T-joints
• The vibration damper/pulley washer

Important

Disassembly of components sealed with RTV requires that specific procedures be followed. SA9123E is required for oil pan removal. The engine's front cover and rear seal carrier have pry tangs to break the component loose from the cylinder block. The cam cover gasket is a precured gasket.

Oil Pan -- In-Chassis

1. Remove the front exhaust pipe.




2. Remove the engine stiffening bracket and flywheel cover.




3. Remove the right-hand side tire, splash shield and vibration damper.
4. Loosen the four front motor mount bolts. Back out the bolts approximately 12 mm (1/2 in).
5. Drain oil.
6. Remove all the oil pan bolts.

Important

An 8 mm flex socket can be used to access the rear oil pan bolt heads next to the flywheel on vehicles with manual transaxles.

7. Pry the front engine mount away from the cylinder block to allow for oil pan removal.




8. Drive the RTV removal tool SA9123E sharp edge between the pan and block.
9. Drive the tool around the pan, shearing the seam. After the pan is loosened, use a rubber mallet and bump the pan sideways to loosen it.

Front Cover -- In-Chassis

Refer to the "Lubrication System" section of this service manual for detailed procedures on front cover assembly removal.

1. Unclip the lower splash shield attachment clips and place a 1 in x 1 in x 2 in long block of wood between the torque strut and cradle.





Important

Installation of the wood block prior to upper engine torque axis mount removal allows the mount to be easily installed without lifting or jacking the powertrain.

2. Remove the 3 right-hand, upper engine torque axis mount to front cover nuts and the 2 mount to midrail bracket nuts, allowing the powertrain to rest on the block of wood, and remove the mount.




3. Remove the accessory drive belt, idler pulley, tensioner assembly, crankshaft damper/pulley, power steering pump, and cam/rocker cover. Refer to "Lubrication System" section for detail.





Notice

Spray the two dowel pin holes in the front cover with penetrating oil to prevent cover damage during removal.

Important

One front cover assembly attachment bolt is located under the torque axis mount flange, above the accessory drive belt idler pulley.

4. Remove the front cover bolts.




5. Pry the cover from the front face of the cylinder block at the upper and lower locations to shear the RTV. A pry bar or large screwdriver can be used.
6. Remove the front cover.

Rear Seal Carrier -- In-Chassis

Important

Screwdriver slots are provided to pry the seal out of the carrier. Use extreme care not to damage the crankshaft sealing surface. The SA9123E is used to install the seal and/or carrier. The tool prevents rolling the seal's lip.

1. Remove the transaxle, flywheel, cover and 2 lower oil pan bolts.
2. Pry tangs are located on both sides of the rear seal carrier. A rolling head pry bar or pinch bar will separate the carrier from the cylinder block.

DOHC (LL0) Black Composite Cam Cover Removal Procedure

DOHC (LL0) engines are assembled with black composite cam covers.

1. Remove the positive crankcase ventilation valve (PVC) hose.
2. Remove the cam cover fasteners.
3. Remove the cam cover assembly.

DOHC (LL0) Black Composite Cam Cover Installation Procedure

Important

Inspect the cam cover isolations for cracks. Replace the isolators if deterioration exist.

Important

Gaskets over one year old may take a set and should be replaced. Gaskets under one year old do not need replacement. A small drop of RTV must be installed at the 2 T-joints whenever the cam cover is installed.

1. Install the new cam cover gaskets, if removed.
2. Install the cam cover assembly.
3. Install the positive crankcase ventilation valve (PVC) hose.

RTV Removal and Surface Preparation

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.

Surfaces to be sealed must be clean and dry. RTV is removed from aluminum surfaces using scrapers, wire brush or Scotch-Brite® Pads and disk (3M® Clean-N Strip® 2 in. D x 1/2 in W x 1/4 in center hole).

The cylinder block, head and front cover holes must be cleaned with a 3/16 in. drill and tap handle. The front cover non tapped holes can be cleaned with a 3/8 in. drill.

Important

Refer to specific sections of manual for additional detail and torque specifications.

Notice

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

After all RTV is removed, clean the surfaces with a chlorinated solvent, such as carburetor spray cleaner, brake clean or alcohol Saturn P//N 21007432 or equivalent, and Scotch-Brite® Pad.

RTV Application and Component Installation

Important

Only the Saturn recommended RTV, Saturn P/N 21006236 or equivalent, should be used. Surfaces to be sealed must be clean and dry. Reference appropriate sections for torque valves.

1. Cut tube opening to approximately 2.0 mm (.080 in) inner diameter.
• Oil Pan: 5.0 mm (0.200 in)
• Front Cover: 2.0 mm (0.080 in)
• Rear Seal Assembly: 2.0 mm (0.080 in.)
• Cam Cover: 2.0 mm (0.080 in)
1. T-joints.
2. When replacing precured gasket.





Important

Follow each surface pattern and maintain the bead diameter cross sections required to ensure the joint is sealed.

Important

Apply bead on the inside edge of the groove as shown.

2. Oil pan.




3. Ensure that the oil pump transfer port seals and front vibration damper/pulley seal are installed correctly.

Important

The front cover oil seal drainback hole and passage way must be kept free of RTV to prevent front seal damage. 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.

Important

Extra RTV is required at oil pan, cylinder head and cam/rocker cover T-joints to make sure gaps are filled to prevent oil leakage. The 1992 and later engines require a RTV bead around the top, center bolt hole.

4. Front cover.

Important

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





5. The front cover cylinder head and block holes must be cleaned with a 3/16 in drill and tap handle. The front cover non tapped holes can be cleaned with a 3/8 in drill.





Notice

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

6. Install the 2 mount to midrail bracket nuts first. Next, install the three 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 upper engine mount-to-front cover to 50 N·m (37 lb ft)

Tighten

Tighten upper engine mount-to-front rail bracket to 50 N·m (37 lb ft)





7. Rear seal assembly.