For 1990-2009 cars

## Engine Front Cover Replacement SOHC

#### Tools Required

SA9104E Front Crank Seal Replacer

1. Clean the front cover and cylinder block 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 a plastic or wood scraper, 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 a 3/8 in drill.

| Notice: 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 Saturn P/N 21007432 or equivalent.

Important: The oil pump must be packed with petroleum jelly for priming if removed or the cylinder block is replaced.

2. Install oil pressure regulator and pump cover if removed.

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

2.1. | If the front seal was removed, use a SA9104E to install a new seal. Never tap on the seal or seal installer with a hammer.

2.2. | Install new oil pressure and suction seals into their respective cavities in the cylinder block.

Important: The front cover oil seal drain back hole and passageway must be kept free of RTV.

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

3. Apply a 4 mm (0.08 in) bead (refer to "RTV" procedure in this service manual) on the front of the oil pan and a 2 mm (0.04 in) bead on the front cover. Install cover immediately.

Notice: A full 2 mm (0.08 in) RTV bead is required on the front cover at the intersection of the front cover and exhaust side of the cylinder head. If too little RTV is applied, an oil leak may occur.

4. Install the crankshaft timing gear retaining service tool SA9104E . It will align the gerotor oil pump during front cover installation.
5. Install the front cover and assembly fasteners and torque in sequence.

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).

6. Install the 4 oil pan fasteners.

Tighten
Tighten the oil pan-to-block to 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: Install a thin film of RTV sealant 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 sealant.

7. Install the water pump pulley, if removed.

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

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

8. Remove the crankshaft timing gear retaining tool and install the crankshaft pulley and the retaining bolt/washer.

Tighten
Tighten the crankshaft pulley bolt (L24) to 215 N·m (159 lb ft).

9. Apply RTV across the cylinder head and front cover T-joints, refer to "RTV" procedure. The rocker cover gasket can be reused if not damaged. Install the rocker cover assembly and tighten the 2 fasteners uniformly.

Tighten
Tighten the rocker arm cover-to-head (L24) to 30 N·m (22 lb ft).

10. Install the belt tensioner.

Tighten
Tighten the belt tensioner-to-block to 30 N·m (22 lb ft).

11. Install the accessory drive belt idler pulley.

Tighten
Tighten the belt idler pulley-to-front cover to 27 N·m (20 lb ft).

12. 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).

13. 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).

14. Install the accelerator linkage bracket and attach the throttle cable. Ensure the throttle cable is properly routed and not binding.

Tighten
Tighten the accelerator control cable bracket-to-intake manifold (L24) to 30 N·m (22 lb ft).

15. Install the following sensors and components:

15.1. | The generator attachment bolts, if removed.

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

15.2. | The starter motor to block, if removed.

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

15.3. | The starter support bracket to axle shaft bracket, if removed.

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

16. Install the power steering pump assembly.

Tighten
Tighten the power steering pump-to-bracket to 30 N·m (22 lb ft).

17. Install the A/C compressor/brackets.

Tighten

• | Tighten the A/C compressor-to-rear bracket to 25 N·m (19 lb ft).

• | Tighten the front A/C bracket-to-block to 47 N·m (35 lb ft).

18. Install the accessory drive belt. Ensure 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.

19. Install the 2 mount to midrail bracket nuts first. Next, install the 3 front upper mount to engine front cover nuts.
20. Remove the block of wood from under the torque strut after the upper mount assembly is installed.

Tighten

• | Tighten the engine mount-to-front cover nuts to 50 N·m (37 lb ft).

• | Tighten the upper mount-to-frame rail bracket to 50 N·m (37 lb ft).

21. Install the splash shield and wheel.

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

22. Connect the following hoses:

• | The EVAP canister purge

• | The throttle body vacuum harness

• | The PCV

• | The fresh air

• | The brake booster

• | The MAP sensor

• | The upper radiator hose

• | The heater hose

23. Install the electrical sensors and the harness connectors:

• | Grounds, if disconnected, at engine/transaxle

Tighten
Tighten the engine/transaxle grounds to 25 N·m (19 lb ft).

• | Oxygen sensor

Tighten
Tighten the oxygen sensor to 25 N·m (19 lb ft).

• | Coolant temperature

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

• | Fuel injectors

• | Idle air control (IAC) valve

• | EGR valve

Tighten
Tighten the EGR valve-to-head top 30 N·m (22 lb ft).

• | Throttle position (TP) sensor

• | EVAP Canister Purge

• | Manifold absolute pressure (MAP) sensor

• | Generator

• | Starter Motor

• | A/C Compressor

24. Install the intake manifold support bracket:

Tighten
Tighten the intake manifold support bracket (L24)-to-block and intake to 30 N·m (22 lb ft).

25. Install the deaeration line fittings and clamps:

• | Deaeration line fitting to the cylinder head and nut to the fitting.

Tighten
Tighten the deaeration line fitting-to-cylinder head (L24) to 9 N·m (80 lb in).

• | Deaeration line to rear lift bracket.

Tighten
Tighten the deaeration line clamp-to-engine bracket (L24) to 11 N·m (97 lb in).

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.

26. Lubricate with clean engine oil the male fuel feed line and the male fuel return line connections. Attach the fuel feed line and pull back to confirm engagement. Attach the fuel return line and pull back to confirm engagement.
27. Install fuel line clip to bracket.

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

28. Install the air cleaner assembly and attach the fresh air hose. Attach the air inlet tube.
29. Fill the engine with new oil.
30. Install the cylinder coolant block drain plug and close the radiator drain.

Tighten
Tighten the cylinder block drain plugs to 5 N·m (26 lb ft).

Important: Vehicle must be level when filling with coolant.

31. Fill with coolant. Use only DEX-COOL™ non-phosphate antifreeze and clean water.
32. Connect the battery terminals.

Tighten
Tighten the Battery Terminal Bolts 17 N·m (13 lb ft).

33. Prime fuel system.

33.1. | Cycle ignition on for 5 seconds and then off for 10 seconds.

33.2. | Repeat step 31.1 twice.

33.3. | Crank engine until it starts, maximum starter motor cranking time is 20 seconds

33.4. | If engine does not start, repeat steps 31.1-31.3 .

34. Start engine and check for leaks.
35. Fill the cooling system surge tank to the FULL COLD line and check for leaks after the engine has been road tested.

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 engine RPM from idle to 3,000 for approximately 10 minutes or drive the vehicle 5 minutes to purge the air. If the air cannot be purged, the faulty lifters will have to be replaced.

36. Perform 3 mile road test and cycle engine under various loads.
37. Check for coolant and oil levels. Verify there are no leaks.

## 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.

1.1. | 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.

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.

24.1. | 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

24.2. | 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.

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.

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.