Timing Cover: Service and Repair
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
Oil pump cover-to-front cover to 11 Nm (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
Front cover perimeter bolts to 30 Nm (22 lb ft).
Front cover lower center bolt (Number 14) to 10 Nm (89 lb in).
6. Install the 4 oil pan fasteners.
Tighten
Oil pan-to-block to 9 Nm (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
Water pump pulley-to-water pump hub to 25 Nm (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
Crankshaft pulley bolt to 215 Nm (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
Rocker arm cover-to-head to 30 Nm (22 lb ft).
10. Install the belt tensioner.
Tighten
Belt tensioner-to-block to 30 Nm (22 lb ft).
11. Install the accessory drive belt idler pulley.
Tighten
Belt idler pulley-to-front cover to 27 Nm (20 lb ft).
12. Drain the engine oil and change the filter. Install the drain plug.
Tighten
Oil pan drain plug to 37 Nm (27 lb ft).
13. Verify the gap on all spark plugs.
Install the spark plugs.
Tighten
Spark plug-to-head to 27 Nm (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
Accelerator control cable bracket-to-intake manifold to 30 Nm (22 lb ft).
15. Install the following sensors and components:
15.1. The generator attachment bolts, if removed.
Tighten
Generator bolts to 32 Nm (24 lb ft).
15.2. The starter motor to block, if removed.
Tighten
Starter motor-to-block to 37 Nm (27 lb ft).
15.3. The starter support bracket to axle shaft bracket, if removed.
Tighten
Starter support bracket-to-axle shaft bracket to 30 Nm (22 lb ft).
16. Install the power steering pump assembly.
Tighten
Power steering pump-to-bracket to 30 Nm (22 lb ft).
17. Install the A/C compressor/brackets.
Tighten
A/C compressor-to-rear bracket to 25 Nm (19 lb ft).
Front A/C bracket-to-block to 47 Nm (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
Engine mount-to-front cover nuts to 50 Nm (37 lb ft).
Upper mount-to-frame rail bracket to 50 Nm (37 lb ft).
21. Install the splash shield and wheel.
Tighten
Wheel nuts to 140 Nm (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
Engine/transaxle grounds to 25 Nm (19 lb ft).
Oxygen sensor
Tighten
Oxygen sensor to 25 Nm (19 lb ft).
Coolant temperature
Tighten
Coolant temperature sensor to 8 Nm (71 lb in).
Fuel injectors
Idle air control (IAC) valve
EGR valve
Tighten
EGR valve-to-head top 30 Nm (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
Intake manifold support bracket (L24)-to-block and intake to 30 Nm (22 lb ft).
25. Install the deaeration line fittings and clamps:
Deaeration line fitting to the cylinder head and nut to the fitting.
Tighten
Deaeration line fitting-to-cylinder head to 9 Nm (80 lb in).
Deaeration line to rear lift bracket.
Tighten
Deaeration line clamp-to-engine bracket to 11 Nm (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
Fuel line retainer clip to 4 Nm (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
Cylinder block drain plugs to 5 Nm (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
Battery Terminal Bolts 17 Nm (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 to 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.