Front Cover and Oil Pump Assembly Installation
IMPORTANT: If a machined front cover casting or assembly is replaced, the torque axis mount studs must be replaced.
Torque: 10 Nm (89 inch lbs.)
1. Clean the front cover and cylinder block mating surfaces:
NOTICE: If excessive wet or dry RTV and oil builds up in the blind holes, the casting will crack when bolts are installed. Make sure all oil galley openings and the oil pan are covered with a shop towel to prevent debris entry.
a. RTV is removed from aluminum surfaces using scraper, plastic or wood, Scotch-Brite Pads, and disk (EMU Clean' N Strip 2 inch D x 1/2 inch W x 1/4 inch center hole).
b. The front cover cylinder head and block holes must be cleaned with a 3/16 inch 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 inch drill.
NOTICE: Do not use petroleum cleaners such as mineral spirits; they leave a film onto which RTV will not stick.
c. After all RTV is removed, clean the surfaces with a chlorinated solvent, such as carburetor spray cleaner, brake cleaner, or alcohol Saturn P/N 21007432 (or equivalent).
1. Install oil pressure regulator, oil pump and pump cover if REMOVED. Use Saturn PIN 21485277 (Loctite 242 Threadlocker or equivalent) on the oil pump cover screws.
Torque: 11 Nm (97 inch lbs.)
IMPORTANT: The oil pump must be packed with petroleum jelly if removed.
2. If front seal was removed, use service tool SA9104E to install a new seal.
3. Install new oil pressure and suction seals into their respective cavities in the cylinder block.
IMPORTANT: Extra RTV is required at oil pan, cylinder head to block, cylinder head and cam/rocker cover T-joints to make sure gaps are filled. A RTV bead around the top, center bolt hole is required.
4. Apply a 4.0 mm (0.157 inch) bead (refer to the RTV) on the front of the oil pan and a 2.0 mm (0.079 inch) bead on the front cover as shown. Install cover immediately. Parts must be assembled within three minutes of application or the material must be removed and applied again.
NOTICE: The front cover oil seal drain back hole and passage way must be kept free of RTV.
IMPORTANT: The crankshaft timing gear retaining tool SA9104E is used to align the gerotor oil pump during front cover installation
5. Install front cover assembly and bolts
6. Install the four front cover oil pan fasteners.
Front Cover (Perimeter, top center) bolts (DOHC [LL0]):
Torque 30 Nm (22 ft. lbs.)
Front Cover Lower Center Bolt (DOHC [LL0]):
Torque: 10 Nm (89 inch lbs.)
Oil Pan:
Torque: 9 Nm (80-lbs.)
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.
- Apply a thin film of RTV sealant P/N 21006236 between 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.
7. Install a new front crankshaft oil seal using service tool SA9104E. Install the vibration damper/pulley assembly and retaining bolt/washer. Never tap on the seal or seal installer with a hammer.
Torque: 215 Nm (159 ft. lbs.)
IMPORTANT: Hold the damper with a strap wrench or use a 3/4 inch x 12 inch long piece of wood wedged between the damper spoke and rear, lower side of cover when torquing bolt.
8. Apply RTV across the cylinder head and front cover T-joints.
9. Install a new cam/rocker cover gasket, if required (refer to the RTV). The gasket can be reused if not damaged.
10. Install the cam/rocker cover.
11. Install the accessory drive belt tensioner.
Torque: 30 Nm (22 ft. lbs.)
12. Install power steering pump (refer to the "Accessory Drive").
13. Install the accessory drive belt. Make sure belt is properly aligned on pulleys.
Torque: 45 Nm (33 ft. lbs.)
NOTICE: To prevent engine front cover and mount damage, the three engine mount to engine front cover nuts must be tightened down uniformly.
14. Install the two engine mount to midrail bracket nuts first. Next, install the three engine mount to engine front cover nuts. Remove the block of wood from under the torque strut after the upper mount assembly is installed.
Engine Mount to Front Cover (Torque Axis Mounts):
Torque: 50 Nm (37 ft. lbs.)
Engine Mount to midrail Bracket (Torque Axis Mounts):
Torque: 50 Nm (37 ft. lbs.)
15. Install splash shield and wheel.
Torque: 140 Nm (103 ft. lbs.)
16. Drain engine oil and change filter. Install drain plug.
Torque: 37 Nm (27 ft. lbs.)
17. Install the battery cables, positive cable first.
Torque: 17 Nm (151 inch lbs.)
18. Fill with new engine oil (API SW30 Energy Conserving II multigrade viscosity oil).
19. Reset "Service Oil Soon" telltale lamp. Refer to "Resetting Service Oil Soon Telltale Lamp".
20. Start engine and check for leaks.
21. Check the engine oil level and fill if necessary.
22. Perform a road test.
23. Check coolant and oil levels. Verify there are no leaks.