Engine Mechanical - 2.4L: Overhaul Saturn Aura I

Engine Block Disassemble

1. Remove the water jacket drain plug.
2. Remove the oil flow check valve.
3. Remove the rear oil passage plug.
4. Remove the 6 oil passage plugs on the sides of the block.
5. Remove the 2 water passage plugs on the top of the block.
6. Remove the 2 front oil passage plugs.
7. Remove the knock sensor and bolt.
8. Remove the oil pressure switch.
9. Remove the crankshaft position (CKP) sensor and bolt.
10. Remove the piston oil squirter bolt.
11. Remove the piston oil squirter.

Cylinder Head Disassemble

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. J 36017 Valve Seal Remover. See «Special Tools»(ref-301512-S32698523102008101700000) .
3. J 43963 Valve Spring Compressor (off car). See «Special Tools»(ref-301512-S32698523102008101700000) .

1. Remove the coolant air bleed hose fitting.
2. Using the J 8062 and the J 43963 , compress the valve spring. See «Special Tools»(ref-301512-S32698523102008101700000) .
3. Remove the valve keys.
4. Slowly release the J 8062 and the J 43963 from the valve spring assembly. See «Special Tools»(ref-301512-S32698523102008101700000) .
5. Remove the retainer.
6. Remove the spring.
7. Remove the valve seal. Use the J 36017 . See «Special Tools»(ref-301512-S32698523102008101700000) . Do not reuse.
8. Remove the valve.
9. Remove the remaining valves.
10. Remove the cylinder head plugs.

Cylinder Head Assemble

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools»(ref-301512-S32698523102008101700000) .
2. J 9666 Valve Spring Tester
3. J 43963 Valve Spring Compressor (off car). See «Special Tools»(ref-301512-S32698523102008101700000) .

1. Install NEW cylinder head plugs. Coat the plugs with sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent.
2. Assemble the valves.
3. Use the following steps to measure valve runout: Apply a dab of Prussian blue on the entire valve face. Seat the valve but do not rotate it. The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat. Clean all traces of Prussian blue. Apply a dab of Prussian blue on the valve seat and repeat the check. The traces of Prussian blue transferred to the valve face indicates valve face concentricity.
4. Replace the valves, if required.
5. Install the new valve seals. Fully seat the seals on the valve guides.
6. Install the spring.
7. Install the retainer.
8. Using the J 8062 and the J 43963 , compress the valve spring. See «Special Tools»(ref-301512-S32698523102008101700000) .
9. Install the valve keys.
10. Slowly release the J 8062 and the J 43963 from the valve/spring assembly. See «Special Tools»(ref-301512-S32698523102008101700000) .
11. Inspect for proper valve key seating.
12. Install the remaining valves, springs, and other components.
13. Install the cylinder head air bleed tube. Tighten: Tighten the tube to 15 N.m (11 lb ft).

Oil Pump Disassemble

1. Disassemble the pressure relief valve.
2. Remove the oil pump gerotor cover and bolts.
3. Clean all of the parts in cleaning solvent. Remove varnish, sludge and dirt.
4. Inspect the oil pump for wear and scoring. Insure that all components are within specifications. Refer to «Engine Mechanical Specifications»(ref-301512-S27176441102008101700000) . Replace the front cover and oil pump assembly if it is out of specification or damaged.

Oil Pump Assemble

1. Lubricate all oil pump parts with engine oil.
2. Install the inner gear into the outer gear.
3. Install the gears together into the front cover with the hub of the center gear facing the front cover.
4. Install the oil pump gerotor cover and bolts. Tighten: Tighten the oil pump gerotor bolts to 6 N.m (53 lb in).
5. Install the pressure relief valve piston.
6. Install the pressure relief valve spring. Tighten: Tighten the pressure relief valve plug to 40 N.m (30 lb ft).

Service Prior to Assembly

The importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.

Engine Block Assemble

1. Install the drain plug in the water pump.
2. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the plug before installation.
3. Install the coolant jacket plugs. Tighten: Tighten the coolant jacket plug to 35 N.m (26 lb ft).
4. Install the rear oil passage plugs.
5. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the plugs before installation. Tighten: Tighten the oil passage plug to 60 N.m (44 lb ft).
6. Install the other oil passage plugs.
7. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the plug before installation. Tighten: Tighten the oil passage plugs to 35 N.m (26 lb ft).
8. Lubricate the crankshaft position sensor O-ring with engine oil.
9. Install the crankshaft position sensor and bolt. Tighten: Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).
10. Install the oil pressure switch. Tighten: Tighten the oil pressure switch to 22 N.m (16 lb ft).
11. Install the knock sensor and bolt. Tighten: Tighten the knock sensor bolt to 25 N.m (18 lb ft).
12. Install the piston oil squirters.
13. Install the piston oil squirter bolts. Tighten: Tighten the piston oil squirter bolts to 15 N.m (11 lb ft).

Balance Shaft Assembly

There are 2 block mounted balance shafts located on each side of the crankcase at the bottom of the cylinder bores. The balance shafts are driven by a single roller chain that also drives the water pump. The chain is tensioned by a hydraulic tensioner that is supplied pressure by the engine oil pump. This design promotes the maximum effectiveness of the balance shaft system and reduces noise and vibration.

Assembling Components

1. When assembling components, use only the sealant specified or equivalent in the service procedure.
2. Sealing surfaces should be clean and free of debris or oil.
3. Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly.
4. Components requiring lubrication will be identified in the service procedure.
5. When applying sealant to a component, apply the amount specified in the service procedure.
6. Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when tightened.
7. Tighten bolts to specifications. Do not overtighten.