Oil Pan: Service and Repair
OIL PAN REMOVAL - IN-CHASSISIMPORTANT: Disassembly of components sealed with RTV requires that specific procedures be followed. RTV cutter tool SA9123E is required for oil pan removal.
1. Remove the front exhaust pipe.
2. On a 1991 powertrain, 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. 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.
6. Pry the front engine mount away from the cylinder block to allow for oil pan removal.
7. Drive the RTV removal tool SA9123E sharp edge between the pan and block.
8. 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.
RTV REMOVAL & SURFACE PREPARATION
NOTICE: If excessive RTV is applied, or oil builds up in the bind holes, the casting will crack when bolts are installed.
^ Surfaces to be sealed must be clean and dry. RTV is removed from aluminum surfaces using scrapers, wire brush or Scotch-Brite(R) Pads and disk (3M(R)) Clean-N Strip(R) 2 in. D x 1/2 in. W x 1/4 in. center hole).
NOTICE: Do not use petroleum cleaners such as mineral spirts; 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 and Scotch-Brite(R) Pad.
RTV APPLICATION & OIL PAN INSTALLATION
IMPORTANT: Only the SATURN recommended RTV (SATURN P/N 21006236, should be used. Surfaces to be sealed must be clean and dry.
1. Cut tube opening to approximately 2.0 mm (0.080 in.) inner diameter.
2. Apply the following RTV bead size to clean surface:
^ Oil Pan: 4.0 mm (0.160 in.).
^ Follow each surface pattern and maintain the bead diameter cross sections required to ensure the joint is sealed.
NOTICE: Apply bead on the inside edge groove as illustrated.
3. Oil pan. Reverse removal procedures to install.
NOTICE: Extra RTV is required at oil pan, cylinder head and cam/rocker cover T-joints to make sure gaps are filled. The 1992-94 engines requires RTV bead around the top, center hole bolt.
NOTICE: Install a thin film of RTV sealant between the vibration damper/pulley assembly flange and washer only.