For 1990-2009 cars

#### Tools Required

SA9104E Front Crank Seal Replacer

Important: If a machined front cover casting or assembly is replaced, the torque axis mount studs must be replaced.

Tighten
Tighten the studs to 10 N·m (89 lb in).

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

| Notice: If excessive wet or dry RTV and 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.

• | RTV is removed from aluminum surfaces using a plastic or wood scraper, Scotch-Brite® Pads, and disk 3M® Clean' N Strip 2 in x 1/2 in. W 1/4 in. center hole.

• | The front cover cylinder head and block 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.

• | After all RTV is removed, clean the surfaces with a chlorinated solvent, such as carburetor spray cleaner, brake cleaner, or alcohol Saturn P/N 21007432 or equivalent.

2. Install the oil pressure regulator, oil pump, and pump cover if removed. Use Saturn P/N 21485277 LOCTITE® 242 Threadlocker or equivalent, on the oil pump cover screws.

Tighten
Tighten the screws to 11 N·m (97 lbs in).

Important: The oil pump must be packed with petroleum jelly if removed.

3. If the front seal was removed, use the SA9104E to install a new seal.
4. Install new oil pressure and suction seals into their respective cavities in the cylinder block.

Important: Extra RTV is required at the oil pan, cylinder head to block, cylinder head, and cam/rocker cover T-joints to make sure the gaps are filled. A RTV bead around the top, center bolt hole is required.

5. Apply a 4 mm (0.157 in) bead on the front of the oil pan and a 2 mm (0.079 in) bead on the front cover as shown. Parts must be assembled within 3 minutes of application or the material must be removed and applied again.

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

Important: The SA9104E is used to align the gerotor oil pump during front cover installation.

6. Install the front cover assembly and bolts.
7. Install the 4 front cover oil pan fasteners.

Tighten
Tighten the front cover (perimeter, top center) bolts (DOHC LL0) to 25 N·m (19 lb ft).

Tighten
Tighten the front cover lower center bolt (DOHC LL0) to 10 N·m (89 lb in).

Tighten
Tighten the oil pan to 9 N·m (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.

Notice: Apply a thin film of RTV sealant P/N 21006236 between damper/pulley assembly flange and washer only. The washer and bolt head flange are designed to prevent oil leakage and do not require RTV sealant.

Important: Hold the damper with a strap wrench or use a 3/4 in. x 12 in. long piece of wood wedged between the damper spoke and rear, lower side of the cover when torquing the bolt.

8. Install a new front crankshaft oil seal using the SA9104E . Install the vibration damper/pulley assembly and retaining bolt/washer. Never tap on the seal or seal installer with a hammer.

Tighten
Tighten the bolt to 215 N·m (159 lb ft).

9. Apply RTV across the cylinder head and front cover T-joints.
10. Install a new cam/rocker cover gasket, if required. The gasket can be reused if not damaged.
11. Install the cam/rocker cover.
12. Install the accessory drive belt tensioner.

Tighten
Tighten the tensioner to 35 N·m (26 lb ft).

13. Install the power steering pump. Refer to Accessory Drive.
14. Install the accessory drive belt. Make sure the belt is properly aligned on the pulleys.

Tighten
Tighten the belt to 45 N·m (33 lb ft).