Engine - Remanufactured Engine Servicing: Overview
NO.: 03-I-01DATE: March, 2003
SUBJECT:
Servicing Remanufactured Engines
TO: All Fixed Operations Managers and Technicians
This Service Information Bulletin is being published to provide important information concerning Saturn's remanufactured engines and cylinder heads made available to Saturn Retailers in January of 2003. A Saturn Service Parts & Accessories Bulletin # 02-PA-03 has been previously published. Please refer to that bulletin for important additional parts and warranty information concerning remanufactured assemblies.
Saturn has recently made available remanufactured engine and cylinder head assemblies. These assemblies will service all 1991-2002 Saturn S-Series 1.9 liter engines. Whenever significant engine and/or cylinder head repairs are necessary, consideration should be given to the use of a remanufactured engine or cylinder head assembly. The applications and part numbers are listed in the tables shown.
Saturn's remanufactured engine and cylinder head assemblies are assembled using new and/or inspected and qualified used parts meeting Saturn's Original Equipment and Service Specifications. Saturn has conducted extensive process and part validation testing and is providing a 36 month or 36,000 mile (whichever comes first) warranty with the remanufactured engine assemblies and a 12 month or 12,000 mile (whichever comes first) warranty with the cylinder head assemblies. Refer to the Warranty Section of this bulletin for additional information and to the Parts & Accessories Bulletin # 02-PA-03 for complete details of the Remanufactured Powertrain Service Parts Warranty.
REMANUFACTURED ENGINE ASSEMBLY INFORMATION
IF THE VEHICLE'S ENGINE EXPERIENCED A SERIOUS MECHANICAL PROBLEM, IT IS POSSIBLE THAT SMALL PIECES OF METAL DEBRIS RESULTING FROM THE PROBLEM MAY HAVE BECOME DEPOSITED IN THE INTAKE MANIFOLD, THE EXHAUST MANIFOLD, THE EXHAUST DOWNPIPE AND/OR THE CATALYTIC CONVERTER. IF THESE PIECES ARE NOT REMOVED PRIOR TO INSTALLING AND OPERATING THE REPLACEMENT ENGINE OR CYLINDER HEAD ASSEMBLY, THE PIECES MAY BE DRAWN INTO THE COMBUSTION CHAMBER AND CAUSE A KNOCKING NOISE AND SUBSEQUENT SERIOUS ENGINE DAMAGE.
Prior to installing and operating the remanufactured engine or cylinder head assembly:
Remove, inspect and thoroughly clean the intake manifold using solvent and compressed air.
Remove, inspect and thoroughly clean the exhaust manifold, downpipe and catalytic converter by inverting, shaking and blowing with compressed air.
Major components that are included with the remanufactured engine assembly (new components are shown in parentheses):
Engine Block
(Pistons, Piston Rings, Pins and Connecting Rods and Bearings)
Crankshaft and (Bearings)
(Oil Pump), Pan and (Filter)
(Water Pump, Thermostat) & Housing
Cylinder Head and (Rocker / camshaft)
Rocker or Camshaft (Cover)
(Timing Chain Components) and Front Cover
Major components that will need to be transferred from the engine being replaced include but are not limited to:
Flexplate or Flywheel
Oil Level Dipstick and Tube
Accessories (AC Compressor, Generator, etc.) and Drive System
Engine Control Sensors (Coolant Temp Sensor, Crankshaft Position Sensor. etc.)
EGR Valve
Ignition Coil Assembly and Spark Plug Wires
Intake and Exhaust Manifolds
Fuel Delivery System (Throttle Body or Fuel injectors and Rail)
REMANUFACTURED CYLINDER HEAD ASSEMBLY INFORMATION
IF THE VEHICLE'S ENGINE EXPERIENCED A SERIOUS MECHANICAL PROBLEM, IT IS POSSIBLE THAT SMALL PIECES OF METAL DEBRIS RESULTING FROM THE PROBLEM MAY HAVE BECOME DEPOSITED IN THE INTAKE MANIFOLD, THE EXHAUST MANIFOLD, THE EXHAUST DOWNPIPE AND/OR THE CATALYTIC CONVERTER. IF THESE PIECES ARE NOT REMOVED PRIOR TO INSTALLING AND OPERATING THE REPLACEMENT ENGINE OR CYLINDER HEAD ASSEMBLY, THE PIECES MAY BE DRAWN INTO THE COMBUSTION CHAMBER AND CAUSE A KNOCKING NOISE AND SUBSEQUENT SERIOUS ENGINE DAMAGE.
Prior to installing and operating the remanufactured engine or cylinder head assembly:
Remove, inspect and thoroughly clean the intake manifold using solvent and compressed air.
Remove, inspect and thoroughly clean the exhaust manifold, downpipe and catalytic converter by inverting, shaking and blowing with compressed air.
Major components that are included with the remanufactured cylinder head assembly (new components are shown with parentheses):
Cylinder Head Machined Casting
Valve Guides and Seats
(Valves), Springs, Caps & (Keys and Seals)
(Spark Plugs)
Major components (if usable) that will need to be transferred from the cylinder head being replaced include but are not limited to:
Engine Control Sensors (MAP Sensor, etc.)
EGR Valve
Intake and Exhaust Manifolds
Fuel Delivery System (Throttle Body or Fuel Injectors and Rail)
Camshaft(s)
Lifters or Hydraulic Lash Adjusters
Rocker Shafts (SOHC) and Rocker Arms
Rocker or Cam Cover
Oil Fill Cap
Suggested parts to have on hand include but are not limited to:
Cylinder Head Gasket
Intake Manifold Gasket
Exhaust Manifold Gasket
EGR Valve Gasket
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