For 1990-2009 cars

#### Tools Required

• | SA9120T Rear Crank Seal Replacer

• | SA9142E Piston Ring Compressor

Important: The engine block requires the location of dowel pins for the front cover, cylinder head, rear crankshaft seal carrier, and transaxle be installed with a brass driver. Dowel pins are installed until they bottom out in the cylinder block.

Important: Thoroughly clean all parts to be assembled. Honed cylinders must be scrubbed with a solution of Tide® powdered laundry detergent, or equivalent, and high pressure warm water prior to piston assembly. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings, and oil seals with new parts.

1. Install the dowel pins using a brass driver.

Important: Install the bearings with the oil holes in the block. The bearings with no holes must go in the main bearing caps.

2. Install the main bearings in the cylinder block and bearing caps.

Important: Inspect the alignment of the bearing oil hole to the block bulkhead oil feed hole. At least 50 percent of the feed hole must be opened/exposed.

3. Install the thrust bearing in the number 3 upper main bearing position of the block.
4. Place the crankshaft in the cylinder block and coat with engine oil.

Important: Bearing caps are numbered 1-5 and have an arrow that points toward the front of the engine. The no. 1 cap is at the front of the cylinder block.

5. Install the main bearing caps.

5.1. | Install the bearing caps in their proper locations. The arrow on the bearing cap points toward the front of the cylinder block.

| Important: Use a rubber mallet and rap the crankshaft rearward and forward in the cylinder block to make sure the thrust bearing is properly aligned.

5.2. | Using a rubber mallet, rap the crankshaft rearward then forward in the cylinder block to align the thrust bearing.

5.3. | Apply a light coat of engine oil on the threads and under the heads of the cap bolts.

5.4. | Install and uniformly tighten the 10 cap bolts in several passes, in an 8, 7, 4, 3, 1, 2, 5, 6, 9, 10 sequence.

Tighten
Tighten the bolts to 50N·m (37 lb ft).

| Important: If the crankshaft does not turn smoothly, remove the bearing caps one at a time until the tight bearing is found. Check the crankshaft journal dimensions and replace the upper and lower bearings as necessary.

5.5. | Check that the crankshaft turns smoothly.

| Important: If a new crankshaft is installed, the PCM will be required to learn the reluctor ring notch locations of the new crankshaft. Refer to Powertrain Control Module.

5.6. | Check the crankshaft thrust clearance. If the clearance is greater than the maximum, replace the thrust bearing.

Specifications

#### Thrust Clearance

• | Standard: 0.05-0.2 mm (0.002-0.0089 in)

• | Service Limit: 0.25 mm (0.0098 in) max.

Important: Do not pull the pistons down through the cylinder bores beyond their normal travel.

6. Install the piston and connecting rod assemblies.

6.1. | Cover the connecting rod bolts with a short piece of 6.36 mm (1/4 in) inside diameter hose to protect the crankshaft from damage. Install the upper connecting rod bearings and coat with oil, if not completed previously.

| Important: Use extreme care when installing the piston and connecting rod. The connecting rod must be properly aligned with the crank pin to prevent journal damage. It is standard practice to assemble the piston and connecting rod with bearing tang slots in the rod directed toward the exhaust manifold side.

6.2. | Using the SA9142E , push the correct piston and connecting rod assembly into each cylinder with the mark on the piston facing forward.

Important: The cap and rod tangs are located on the same side of the connecting rod bore.

7. Install the connecting rod caps.

7.1. | Match the marked cap with the marked connecting rod.

7.2. | Install the lower connecting rod bearings in the cap. Apply a light coat of oil on the bearing surface.

| Important: The machined slots in the rod and cap must be properly aligned to prevent bearing damage.

7.3. | Install the cap with the bearing tang slots in the cap and connecting rod facing each other.

7.4. | Apply a light coat of engine oil on the bolt threads and under the nuts of the connecting rod cap.

7.5. | Install and alternately tighten the cap nuts in several passes.

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

7.6. | Check that the crankshaft turns smoothly.

| Important: If clearance is less or greater than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

7.7. | Check the connecting rod side clearance.

Specifications

#### Side Clearance

• | Standard: 0.165-0.435 mm (0.0065-0.1713 in)

• | Service Limit: 0.47 mm (0.185 in) max.

Notice: Check the oil seal lip contact surface of the crankshaft for scratches or damage. If rust is present, remove with a Scotch-Brite® pad or equivalent. Do not use emery cloth, sandpaper, or other abrasive materials. Rust removal is necessary to prevent seal lip damage during installation.

8. Install the rear oil seal carrier and seal if required.

Specifications

#### Piston Protrusion Above Deck of Block

• | Standard: 0.3 mm (0.0118 in) max.

• | Service Limit: 0.379 mm (0.0149 in) max.

Specifications

#### Piston Protrusion Below Deck of Block

• | Standard: 0.066 mm (0.0026 in) max.

• | Service Limit: 0.145 mm (0.0057 in) max.

8.1. | Make sure the surface is free of RTV and clean with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol Saturn P/N 21007432, or equivalent.

8.2. | Install a 2 mm (0.08 in) diameter bead of RTV on the rear seal carrier.

Important: Assemble while the RTV is still wet, within 3 minutes. Do not wait for the RTV to skin over.

9. Install the 4 rear crankshaft seal carrier bolts. Use the SA9121E as a pilot to make sure the seal lip is not damaged during carrier assembly installation.

Tighten
Tighten the bolts to 11 N·m (97 lb in).

10. Refer to the cylinder head section of this manual for cylinder head and front cover installation.

Important: Check components for debris. Clean all parts before installation.

11. Install the oil baffle plate DOHC (LL0) and pickup tube with a new O-ring.

Tighten

• | Tighten the oil pickup tube to block to 15 N·m (133 lb in).

• | Tighten the oil baffle plate DOHC (LL0) to 55 N·m (41 lb ft).

• | Tighten the oil pipe bracket to block SOHC (L24) to 55 N·m (41 lb ft).

• | Tighten the oil pipe bracket to baffle plate DOHC (LL0) to 15 N·m (133 lb in).

Important: The oil pan is easier to install after the front cover assembly installation.

Important: Assemble while the RTV is still wet, within 3 minutes. Do not wait for the RTV to skin over.

12. Install the oil pan assembly and fasteners.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

12.1. | Make sure the oil pan surface is free of cured RTV and cleaned with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol Saturn P/N 21007432, or equivalent.

12.2. | Apply a 4 mm (0.16 in) bead of RTV in the oil pan groove, routing the RTV bead toward the inside of all bolt holes.

13. Install the water pump.

Install a new gasket. Use a small amount of RTV in 3-4 spots around the outer bolt holes to hold the gasket in place. Refer to the engine cooling section for water pump installation.

Tighten

• | Tighten the water pump to 30 N·m (22 lb ft).

• | Tighten the water pump pulley to 25 N·m (19 lb ft).

14. Install the dipstick tube with a new O-ring. Lubricate the O-ring with engine oil and install into the cylinder block. Attach the tube bracket to the cylinder block.

Tighten
Tighten the screw to 30 N·m (22 lb ft).

15. Install the flexplate or flywheel. The flexplate and flywheel can be installed at any bolt hole location. The flexplate or flywheel can be held with a flywheel turning tool when tightening the bolts.

Tighten

• | Tighten the flexplate to crankshaft bolts to 60 N·m (44 lb ft).

• | Tighten the flywheel to crankshaft bolts to 80 N·m (59 lb ft).

Important: Additional component and sensor torques are found in the appropriate cylinder head and engine installation sections.

16. Install the following accessories.

16.1. | Knock sensor

Tighten
Tighten the knock sensor to 15 N·m (133 lb in).

16.2. | Crankshaft position sensor -- Lubricate the O-ring with oil before installation.

Tighten
Tighten the crankshaft position sensor to 9 N·m (80 lb in).

| Important: Whenever the cylinder block has been disassembled or the oil pump is removed, fill the oil cavity under the oil filter with clean engine oil to prime the pump. The oil pump must also be packed with petroleum jelly as outlined in the Lubrication System section.

16.3. | Starter motor to block

Tighten
Tighten the starter motor to block to 37 N·m (27 lb ft).

16.4. | Generator

Tighten
Tighten the generator to 32 N·m (24 lb ft).

16.5. | Oil filter

Tighten
Tighten the oil filter to gasket contact and 3/4-1 turn.

16.6. | Oil pan drain plug

Tighten
Tighten the oil pan drain plug to 37 N·m (27 lb ft.

16.7. | Oil pressure sending unit

Tighten
Tighten the oil pressure sending unit to 35 N·m (26 lb ft).

16.8. | Flywheel

Tighten
Tighten the flywheel to 80 N·m (59 lb ft).

16.9. | Flexplate

Tighten
Tighten the flexplate to 60 N·m (44 lb ft).