- 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.
|
| 1.1. | 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). |
| 1.2. | 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.
|
| 1.3. | After all RTV is removed, clean the surfaces with a chlorinated solvent, such
as carburetor spray cleaner, brake clean, or alcohol. |
Notice: Refer to Fastener Notice in the Preface section.
Important: If removed, the oil pump must be packed with
petroleum jelly for printing.
- 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).
- 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.
- 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.
- 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.
- Install the front crank seal using the SA9104E
. The tool aligns the
generator pump during front cover installation.
- 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 (14) to 10 N·m
(89 lb in). |
- 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.
- 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.
- 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).
- 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.
- 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).
- 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).
- 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).
- 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.
- 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). |
- Install generator attachment bolts/nut (both), if removed.
Tighten
Tighten the generator bolts to 32 N·m
(24 lb ft).
- 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). |
- 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). |
- 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.
- 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). |
- Install splash shield and wheel.
Tighten
Tighten the wheel nuts to 140 N·m (103 lb ft).
- Install the following sensors and components:
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).
Tighten
Tighten the EGR valve-to-head 25 N·m
(19 lb ft).
- Install the following sensors and electrical harness connectors and vacuum
hoses.
| 24.1. | Electrical Connectors: |
| • | Grounds, if disconnected |
| • | Coolant temperature sensor |
| • | Throttle position (TP) sensor |
- Install the accelerator cable to the bracket
and attach the throttle cable. Ensure the throttle cable is properly routed and not
binding.
- Install the coolant hoses.
| • | 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.
- Lubricate with clean engine oil the male fuel feed line. Attach the fuel feed
line and pull back to confirm engagement.
- Install the fuel line clip to the intake manifold stud.
Tighten
Tighten the fuel line retainer clip to 4 N·m
(35 lb in).
- 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). |
- Install the air intake resonator, tube, filter cover and clamps. Refer
to Induction section of this service manual.
- Connect the battery cables, positive cable first.
Tighten
Tighten the battery terminal bolts to 17 N·m
(13 lb ft).
- 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).
- 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.
- Fill with coolant. Use only DEX-COOL™ ethylene glycol-based antifreeze.
- Prime the fuel system.
| 35.1. | Cycle the ignition on for 5 seconds and then off for 10 seconds. |
| 35.2. | Repeat step 31.1 twice. |
| 35.3. | Crank engine until it start, maximum starter motor cranking time is 20 seconds. |
- 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.
- Perform a 3 mile road test.
- Fill the cooling system surge tank to the FULL COLD line and check for
leaks after the engine has been tested.
