GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Rear Main Seal

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REMOVAL & INSTALLATION



1.8L, 2.0L and 2.2L OHV Engines
1982-84 VEHICLES WITH TWO PIECE SEAL

See Figures 1 and 2

  1. Remove the oil pan and pump.
  2.  
  3. Remove the rear main bearing cap.
  4.  
  5. Gently pack the upper seal into the groove approximately 1 / 4 in. (6mm) on each side.
  6.  
  7. Measure the amount the seal was driven in on one side and add 1 / 16 in. (0.8mm). Cut this length from the old lower cap seal. Be sure to get a sharp cut. Repeat for the other side.
  8.  
  9. Place the piece of cut seal into the groove and pack the seal into the block. Do this for each side.
  10.  
  11. Install a piece of Plastigage® or the equivalent on the bearing journal. Install the rear cap and tighten to 75 ft. lbs. Remove the cap and check the gauge for bearing clearance. If out of specification, the ends of the seal may be frayed or not flush, preventing the cap from proper seating. Correct as required.
  12.  
  13. Clean the journal, and apply a thin film of sealer to the mating surfaces of the cap and tighten to 70 ft. lbs. (95 Nm). Install the pan and pump.
  14.  

Some 1982 1.8L engines (Code G), experience a rear main seal oil leak. To correct this condition a new crankshaft part No. 14086053 and a one piece rear main seal kit part No. 14081761 has been released for service. The one piece seal kit contains an installation tool, rear main seal, and an instruction sheet.

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Fig. Fig. 1: Apply sealer to the rear cap



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Fig. Fig. 2: Use the bearing cap to hold the old lower seal while you cut it

1985-94 VEHICLES WITH ONE PIECE SEAL

See Figures 3 and 4

  1. Jack up the engine and support it safely.
  2.  
  3. Remove the transmission as outlined in Drive Train .
  4.  
  5. Remove the flywheel.
  6.  
  7. Insert a suitable pry tool in through the dust lip and pry out the seal by moving the tool around the seal until it is removed.
  8.  

Use care not to damage the crankshaft seal surface with a pry tool.

To install:
  1. Before installing, lubricate the seal bore to seal surface with engine oil.
  2.  
  3. Install the new seal using tool J-34686.
  4.  
  5. Slide the new seal over the mandrel until the dust lip bottoms squarely against the tool collar.
  6.  
  7. Align the dowel pin of the tool with the dowel pin hole in the crankshaft and attach the tool to the crankshaft. Tighten the attaching screws to 2-5 ft. lbs. (2.7-6.8 Nm).
  8.  



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Fig. Fig. 3: Removing the old seal - 1985-94 OHV engines



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Fig. Fig. 4: Installation of the one piece seal - 1982-94 OHV engines

  1. Tighten the T-handle of the tool to push the seal into the bore. Continue until the tool collar is flush against the block.
  2.  
  3. Loosen the T-handle completely. Remove the attaching screws and the tool.
  4.  

Check to see that the seal is squarely seated in the bore.

  1. Install the flywheel and transmission.
  2.  
  3. Start the engine and check for leaks.
  4.  

1.8L and 2.0 OHC Engines

See Figure 5

The rear main bearing oil seal is a one piece unit and can be replaced without removing the oil pan or the crankshaft.

  1. Remove the transaxle assembly as outlined in Drive Train .
  2.  
  3. Remove the flywheel retaining bolts and remove the flywheel.
  4.  
  5. If equipped with manual transaxle, remove the pressure plate and disc.
  6.  
  7. Pry out the rear main seal.
  8.  
  9. Clean the block and crankcase to seal mating surfaces.
  10.  

To install:
  1. Position the rear main seal to the block and press evenly into place using tool J33084 (1983-86) or tool J-36227 (1987-94 vehicles). Lubricate the outside of the seal to aid assembly.
  2.  
  3. Use new bolts and install the flywheel, then tighten the bolts to 44 ft. lbs. (60 Nm) on 1983-86 vehicles, or 48 ft. lbs. (65 Nm) plus a 30° turn on 1987-94 vehicles.
  4.  



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Fig. Fig. 5: Installation of the one piece seal - 1983-86 OHC engines

  1. On automatic transaxle models, install the flexplate and tighten to 48 ft. lbs. (65 Nm).
  2.  
  3. Install the pressure plate and disc, if equipped with manual transaxle.
  4.  
  5. Install the transaxle assembly as outlined in Drive Train .
  6.  

2.8L and 3.1L Engines

See Figures 6, 7 and 8

  1. Support the engine with J-28467 engine support or equivalent.
  2.  
  3. Remove the transaxle as outlined in Drive Train .
  4.  
  5. Remove the flywheel.
  6.  
  7. Insert a suitable pry tool in through the dust lip and pry out the seal by moving the tool around the seal until it is removed.
  8.  


WARNING
Use care not to damage the crankshaft seal surface with a pry tool.

Click image to see an enlarged view

Fig. Fig. 6: When removing the rear main seal, be careful not to scratch the bore


To install:
  1. Before installing, lubricate the seal bore to seal surface with engine oil.
  2.  
  3. Install the new seal using tool J-34686.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: A special tool is needed to install the rear main seal

  1. Slide the new seal over the mandrel until the dust lip bottoms squarely against the tool collar.
  2.  
  3. Align the dowel pin of the tool with the dowel pin hole in the crankshaft and attach the tool to the crankshaft. Tighten the attaching screws to 2-5 ft. lbs. (2.7-6.8 Nm).
  4.  
  5. Tighten the T-handle of the tool to push the seal into the bore. Continue until the tool collar is flush against the block.
  6.  
  7. Loosen the T-handle completely. Remove the attaching screws and the tool.
  8.  

Check to see that the seal is squarely seated in the bore.

Click image to see an enlarged view

Fig. Fig. 8: Installing the rear main seal - 1994 3.1L engine shown

  1. Install the flywheel and transaxle.
  2.  
  3. Start the engine and check for leaks.
  4.  

 
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