Engine Mechanical - 3.5L (L66): Overhaul Saturn VUE I

Cylinder Head Disassemble

Tools Required

1. EN 46353 Valve Spring Compressor Attachment - Head Off-Vehicle. See Special Tools and Equipment .
2. SA9102E-A Valve Seal Remover/Replacer. See Special Tools and Equipment .
3. SA9124E Regulator Valve Remover/Replacer. See Special Tools and Equipment .

1. Using an appropriate size socket and a plastic-faced hammer, lightly tap the valve cap in order to loosen the keys.
2. Use the SA9124E (2). See Special Tools and Equipment . EN 46353 (1) in order to compress the valve spring. See Special Tools and Equipment .
3. Remove the keys (206), cap (205), spring (204), and valve (222).
4. Using the SA9102E-A , remove the seal (266) and seat (265). See Special Tools and Equipment .

Cylinder Head Assemble

Tools Required

1. EN 46336 Valve Guide Seal Installer. See Special Tools and Equipment .
2. EN 46353 Valve Spring Compressor Attachment - Head Off-Vehicle. See Special Tools and Equipment .
3. SA9124E Regulator Valve Remover/Replacer. See Special Tools and Equipment .

1. Install the seats (202).
2. Lubricate the valve stem oil seals (203) with clean engine oil.
3. Use the EN 46336 in order to install the valve stem oil seals onto the guides. See Special Tools and Equipment . Intake valve seals have a white spring (1). Exhaust valve seals have a black spring (2).
4. Install the valves (222), springs (204) and caps (205).
5. Use the SA9124E (2) and the. See Special Tools and Equipment . EN 46353 (1) in order to compress the valve spring. See Special Tools and Equipment .
6. Install the valve stem keys and remove the SA9124E (2) and. See Special Tools and Equipment . EN 46353 (1). See Special Tools and Equipment .
7. Using a plastic-faced hammer, lightly tap the end of each valve stem 2-3 times to ensure proper seating of the valve and keys.

Oil Pump Disassemble

1. Remove the oil pressure switch (705).
2. Remove the crankshaft front oil seal (419).
3. Remove the O-ring (406).
4. Remove the bolts (435) and cover (434).
5. Mark the inner and outer rotors with a paint stick in order to return to original direction during assembly.
6. Remove the inner rotor (432) and outer rotor (433).
7. Remove the bolt (422), spring (421), and valve (420).
8. Remove the plugs (438 and 439).

Oil Pump Assemble

Tools Required

1. EN 46342 Driver Handle
2. EN 46347 Crankshaft Front Oil Seal Driver. See Special Tools and Equipment .

1. Lubricate the rotors (432, 433) and valve (420) with clean engine oil.
2. Install the rotors (432, 433) to original direction.
3. Install the cover (434).
4. Apply threadlock GM P/N 12346240 (Canadian P/N 10953493) or equivalent to the threads of the bolts (435).
5. Install the bolts (435). Tighten: Tighten the bolts to 6 N.m (53 lb in).
6. Apply sealant GM P/N 12346240 (Canadian P/N 10953493) to the threads of the bolt (422).
7. Install the valve (420), spring (421) and bolt (422). The valve must slide freely in the housing bore. Tighten: Tighten the bolt to 39 N.m (28 lb ft).
8. Apply sealant GM P/N 12346240 (Canadian P/N 10953493) or equivalent to the threads of the switch (705).
9. Install the switch (705). Tighten: Tighten the switch to 18 N.m (13 lb ft).
10. Apply sealant GM P/N 12346240 (Canadian P/N 10953493) to the threads of the plugs (438, 439).
11. Install the plugs (438, 439). Tighten: Tighten plug (438) to 44 N.m (32.5 lb ft). Tighten plug (439) to 34.3 N.m (25.3 lb ft).
12. Use the EN 46347 (2) and the. See Special Tools and Equipment . EN 46342 (1) in order to install the oil seal. Gently tap and install the NEW oil seal until the tool bottoms on the oil pump housing.

Service Prior to Assembly

1. Dirt or debris will cause premature wear of the rebuilt engine. Clean all the components. Refer to Cleanliness and Care .
2. Use the proper tools to measure components when checking for excessive wear. Components that are not within the manufacturers specifications must be repaired or replaced.
3. When the components are reinstalled into an engine, return the components to their original location, position and direction. Refer to Separating Parts .
4. During assembly, lubricate all the moving parts with clean engine oil. This will provide initial lubrication when the engine is first started.

Piston and Connecting Rod Assemblies

The pistons are cast aluminum with a flat top design. Piston skirts are coated to reduce friction. Each piston uses 2 compression rings and 1 3-piece oil control ring assembly. The piston pin is a full-floating design and is retained to the connecting rod by clips located in each end of the piston pin bore. The connecting rod and rod cap are positioned and aligned by a dowel pin and retained by bolts.

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.