Cylinder Head: Removal & Installation Saturn SL II

Removal

1. Disconnect negative battery cable. Drain coolant. Remove air cleaner assembly. Disconnect accelerator cable. Disconnect wiring harness from engine and secure to underhood junction block. Disconnect upper radiator hose, and heater hose from intake manifold. Remove A/C compressor (leave hoses connected). Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-1450-S39821245792000031300000). Disconnect fuel lines and secure to brake booster.
2. Remove front cover and timing chain. See «FRONT COVER & TIMING CHAIN»(ref-1450-S18957452602000031300000). Using a 6-point socket (a 12-point socket will round off bolt heads), uniformly loosen cylinder head bolts in reverse order of tightening sequence, in several stages. (Scheme 9)or (Scheme 10). Remove cylinder head.

Installation

Install NEW head gasket. Install cylinder head. Tighten cylinder head bolts to specification in proper sequence. (Scheme 9)or (Scheme 10). Install timing chain and front cover. See FRONT COVER & TIMING CHAIN. To install remaining components, reverse removal procedure. Fill cooling system. Fill crankcase. Check for leaks.

Scheme 9

Scheme 10

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. Put a block of wood between cradle and engine torque strut at bottom front end of engine. see scheme 3
2. Remove mount from upper front end of engine, allowing engine to rest on wood block. Remove accessory drive belt and tensioner. Remove accessory belt idler. Remove cylinder head cover. Replace silicone isolators on cylinder head cover screws if deteriorated. Remove power steering pump (leave hoses attached). Remove A/C compressor (leave hoses attached).
3. Remove intake manifold support bracket (DOHC). Remove front balancer/pulley using a 3-jaw puller. Disconnect exhaust pipe from exhaust manifold. Install Crankshaft Gear Retainer (SA9104E) onto end of crankshaft. Crankshaft gear retainer holds crankshaft gear in place during removal of front cover. CAUTION: When installing Crankshaft Gear Retainer (SA9104E), install with flat side toward crankshaft gear (sprocket). Failure to hold crankshaft timing gear (sprocket) will damage timing chain guide. After front cover assembly is loosened and moved about 1" from engine block, remove Crankshaft Gear Retainer (SA9104E).
4. Remove 4 bolts from front end of oil pan. Using RTV Cutter (SA9123E), cut RTV sealant between oil pan and front cover. Spray penetrating oil onto front cover dowel pins. Remove front cover bolts (one bolt is located above accessory drive belt pulley on DOHC). Pry front cover from engine block, using pry locations shown. (Scheme 11) WARNING: The camshafts can rotate during timing chain and sprocket removal. Keep fingers and tools away from sprockets and chain.
5. To prevent pistons from hitting valves, turn crankshaft 90 degrees clockwise as viewed from front of engine until timing mark and keyway are aligned with split line of main bearing cap. Remove timing chain tensioner, guides and chain. While using a 7/8" (21 mm) wrench to keep camshaft(s) from turning, remove camshaft sprocket bolt(s). Remove camshaft sprocket(s).

Scheme 11

1. To prevent pistons from hitting valves, ensure timing mark and keyway on crankshaft are aligned with split line of main bearing cap. Install camshaft sprocket(s) with the letters FRT (front) facing away from cylinder head.
2. Rotate camshaft until a 3/16" (4.8 mm) drill bit can be inserted through pin hole and into cylinder head. (Scheme 12)or (Scheme 13). Use a 7/8" (21 mm) wrench to keep camshaft(s) from turning. Install and tighten camshaft sprocket bolt(s) to specification. Rotate crankshaft(s) counterclockwise as viewed from front of engine until timing marks at crankshaft sprocket are aligned. Install timing chain, aligning Silver-plated chain links with marks on sprockets. (Scheme 12)or (Scheme 13).
3. Install fixed chain guide. Slack part of chain should be on tensioner side of cylinder block. Chain should be tight against fixed chain guide. Install pivoting chain guide. Retract tensioner plunger, and insert a 1/8" or No. 31 (3.2 mm) drill bit into lever locking hole. Install tensioner.
4. Check timing mark alignment. Remove drill bits from camshaft sprockets and tensioner. If oil pump and pressure regulator were removed from front cover, install them using special procedures. See «OIL PUMP»(ref-1450-S41081475132000031300000) under ENGINE OILING. If front seal was removed, press NEW seal into front cover using Seal Installer (SA9104E). CAUTION: DO NOT allow RTV sealant to clog oil passage holes, including drain-back hole at bottom of oil seal.
5. Install NEW oil pressure seal (pump outlet) and suction seal (pump inlet) into cavities in cylinder block. Apply a.16" (4 mm) bead of RTV sealant to oil pan sealing surface. Apply a.08" (2 mm) bead of RTV sealant to front cover sealing surface. Apply RTV sealant to bolt hole in the middle of the cover above oil pump (and top center of front cover on DOHC). Apply extra RTV sealant to joint where head meets block. Install front cover immediately.
6. Install Crankshaft Gear Retainer (SA9104E) to align oil pump drive gear. Tighten front cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1450-S40274644912000031300000) table. NOTE: After front cover is installed, 6-12 squirts of oil should be pumped through the front seal drain back hole to ensure it is not plugged.
7. Install cylinder head cover. If silicone isolators are deteriorated, replace them. Tighten cylinder head cover bolts to specification (start at center and work outward). To complete installation, reverse removal procedure.

Scheme 12

Scheme 13