Assembly

1. Clean the front cover and cylinder block mating surfaces:

CAUTION: If excessive RTV is applied, or oil builds up in the blind holes, the casting will crack when bolts are installed. Make sure all oil gallery openings and the oil pan are covered with a shop towel to prevent debris entry.

a. RTV is removed from aluminum surfaces using a plastic or wood scraper, Scotch-Brite Pads, and disk (EMU Clean-N Stripe 2 inch D x 1/2 inch W x 1/4 inch center hole).
b. The front cover, cylinder head and block bolt 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.

CAUTION: 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 clean, or alcohol Saturn P/N 21007432 (or equivalent).

CAUTION: 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. Torque to 11 Nm (97 inch lbs.).





a. If front seal was removed, use service tool SA9104E to install a new seal. Never tap on the seal or seal installer with a hammer.
b. Install new oil pressure and suction seals into their respective cavities in the cylinder block.

CAUTION: The front cover oil seal drain back hole and passage way must be kept free of RTV. 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.





c. Apply a 4.0 mm (0.080 inch) bead on the front of the oil pan and a 2.0 mm (0.040 inch) bead on the front cover. Install cover immediately.





3. Install the crankshaft timing gear retaining service tool SA9104E. It will align the gerotor oil pump during front cover installation.





4. Install the front cover and assembly fasteners and torque in sequence:
^ Front Cover (Perimeter Bolts): Torque to 30 Nm (22 ft. lbs.).
^ Front Cover Lower Center Bolt (Number 14): Torque to 10 Nm (89 inch lbs.)
5. Install the four oil pan fasteners: Torque to 9 Nm (80 inch lbs.)





CAUTION: After the front cover is installed, 6 to 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.





6. Install water pump pulley, if removed: Torque to 25 Nm (19 ft. lbs.)

CAUTION: 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. Remove the crankshaft timing gear retaining tool and install crankshaft pulley and retaining bolt/washer. Hold 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. Torque to 215 Nm (159 ft. lbs.).





8. Apply RTV across the cylinder head and front cover T-joints. The rocker cover gasket can be reused if not damaged. Install rocker cover assembly and tighten the two fasteners uniformly. Torque to 30 Nm (22 ft. lbs.).
9. Install belt tensioner. Torque to 30 Nm (22 ft. lbs.).
10. Install the accessory drive belt idler pulley. Torque to 27 Nm (20 ft. lbs.).
11. Drain engine oil and change filter. Install drain plug. Torque is 35 Nm (26 ft. lbs.).
12. Verify gap on all spark plugs.
a. Install spark plugs. Torque to 27 Nm (20 ft. lbs.).





13. Install accelerator linkage bracket and attach throttle cable. Make sure the throttle cable is properly routed and not binding. Torque to 25 Nm (19 ft. lbs.).
14. Install the following sensors and components:
a. Generator attachment bolts, if removed. Torque to 32 Nm (24 ft. lbs.).
b. Starter motor to block, if removed. Torque to 37 Nm (27 ft. lbs.).
c. Starter support bracket to axle shaft bracket, if removed. Torque to 30 Nm (22 ft. lbs.).
15. Install power steering pump assembly. Torque to 30 Nm (22 ft. lbs.).
16. A/C compressor/brackets.
^ Rear bracket to block and compressor. Torque to 25 Nm (19 ft. lbs.).
^ Front bracket to block and compressor. Torque to 47 Nm (35 ft. lbs.).
17. Install accessory drive belt. Make sure the belt is properly aligned on the pulleys.

CAUTION: To prevent [1][2]engine front cover and mount damage, the three front upper mount to engine front cover nuts must be tightened down uniformly.





18. Install the two mount to midrail bracket nuts first. Next, install the three front upper mount to [1][2]engine front cover nuts. Remove the block of wood from under the torque strut after the upper mount assembly is installed.
^ Upper Mount to Front Cover: Torque to 50 Nm (37 ft. lbs.).
^ Upper Mount to Frame Rail Bracket: Torque to 50 Nm (37 ft. lbs.).
19. Install the splash shield and wheel. Torque to 140 Nm (103 ft. lbs.).
20. Connect the following hoses:
^ EVAP cannister purge
^ Throttle body vacuum harness
^ PCV
^ Fresh air
^ Brake booster
^ MAP sensor
^ Upper radiator hose
^ Heater hose
^ Fuel pressure regulator
21. Install electrical sensors and harness connectors:
^ Grounds (if disconnected) at engine/transaxle: Torque to 25 Nm(19 ft. lbs.)
^ Oxygen sensor. Torque to 25 Nm (19 ft. lbs.).
^ Coolant temperature (two separate sensors). Torque to 8 Nm (71 inch lbs.).
^ Fuel injectors.
^ Idle air control (IAC).
^ EGR valve. Torque to 25 Nm (19 ft. lbs.).
^ Throttle position (TP) sensor.
^ EVAP Canister Purge.
^ Manifold air pressure (MAP).
^ Generator.
^ Starter Motor.
^ A/C Compressor.
22. Install intake manifold support bracket:
^ Bracket to intake manifold. Torque to 30 Nm (22 ft. lbs.).
^ Bracket to block. Torque to 30 Nm (22 ft. lbs.).
23. Install deaeration line fittings and clamps:
^ Deaeration line fitting to cylinder head and nut to fitting. Torque to 9 Nm (80 inch lbs.).
^ Deaeration line to rear lift bracket. Torque to 11 Nm (97 inch lbs.).

CAUTION: Replace plastic fuel line retainers whenever the fuel supply or return line 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 and male ends together until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

NOTE: The service retainers are different in color from the original equipment retainers. The service fuel feed line retainers are clear in color.

24. 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.
25. Install fuel line clip to bracket. Torque to 6 Nm (53 inch lbs.).
26. Install air cleaner assembly and attach the fresh air hose. Attach air inlet tube.
27. Install oil pan drain plug and fill engine with new oil. Torque to 37 Nm (27 ft. lbs.).
28. Install cylinder coolant block drain plug and close radiator drain. Torque to 30 Nm (22 ft. lbs.).
29. Fill with coolant. Use only a non-phosphate ethylene glycol-based antifreeze.

NOTE: Vehicle must be level when filling with coolant.

30. Connect the battery terminals. Torque to 17 Nm (151 inch lbs.).
31. Prime fuel system.
a. Cycle ignition on for five seconds and then off for ten seconds.
b. Repeat step 31a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds)
d. If engine does not start, repeat steps 31a-c.
32. Start engine and check for leaks.
33. Fill the cooling system surge tank to the FULL COLD line and check for leaks after the engine has been road tested.

CAUTION: Allow the engine to idle for three to five minutes. If lifters are noisy or cylinders are mis-firing, 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 five minutes to purge the air. If the air cannot be purged, the faulty lifter(s) will have to be replaced.

34. Perform three mile road test and cycle engine under various loads.
35. Check for coolant and oil levels. Verify there are no leaks.