GM Malibu/Cutlass 1997-2000

Rear Main Seal

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REMOVAL & INSTALLATION



2.4L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the transaxle assembly as outlined in of this guide.
  4.  
  5. Unfasten the flywheel-to-crankshaft bolts, then remove the flywheel.
  6.  
  7. Disconnect the oil pan-to-seal housing bolts
  8.  
  9. Unfasten the seal housing-to-block bolts, then remove the seal housing and gasket.
  10.  
  11. To support the seal housing for seal removal, place two blocks of equal thickness on a flat surface, position the seal housing and blocks so the transaxle side of the seal housing is supported across the dowel pin and center bolt holes on both sides of the seal opening.
  12.  


NOTE
The seal housing could be damaged if not properly supported during seal removal.

  1. Drive the seal evenly out the transaxle side of the seal housing using a small prytool in the relief grooves on the crankshaft side of the seal housing. Discard the seal.
  2.  


WARNING
Be careful not to damage the seal housing sealing surface. If damaged, it may result in an oil leak.



Click image to see an enlarged view

Fig. Rear main seal and housing-2.4L engine



Click image to see an enlarged view

Fig. The rear main seal may be installed using a suitable seal driver tool and a hammer

To install:

  1. Press a new seal into the housing using a seal installation tool.
  2.  
  3. Inspect the oil pan gasket inner silicone bead for damage and repair using a silicone sealant, if necessary.
  4.  
  5. Position a new seal housing-to-block gasket over the alignment. The gasket is reversible.
  6.  
  7. Lubricate the lip of the seal with clean engine oil.
  8.  
  9. Install the housing assembly.
  10.  
  11. Install the oil pan-to-seal housing bolts. Tighten, referring to torque specifications chart in this section.
  12.  
  13. Install the flywheel as outlined later in this section.
  14.  
  15. Install the transaxle assembly as outlined in of this guide.
  16.  
  17. Connect the negative battery cable, then start the engine and check for leaks.
  18.  

3.1L Engine

The following tools may be required to replace the rear main seal:



Engine support fixture
 
Engine support fixture adapters
 
Rear main bearing oil seal installer
 
Engine support adapter leg
 


NOTE
The engine will have to be raised and supported and the transaxle removed to perform this procedure.

  1. Disconnect the negative battery cable.
  2.  
  3. Support the engine with the appropriate fixtures.
  4.  
  5. Remove the transaxle as outlined in of this guide.
  6.  
  7. Unfasten the flywheel mounting bolts, then remove the flywheel and spacer.
  8.  
  9. Using a small prybar, pry the seal from the block.
  10.  


CAUTION
Be careful not to damage the crankshaft surface when removing the oil seal.



Click image to see an enlarged view

Fig. Use a suitable prytool to remove the rear main seal

  1. Clean the seal mounting surface.
  2.  

To install:

  1. Coat the inside and outside of the new rear main oil seal with engine oil.
  2.  
  3. Install the new seal on tool until the seal bottom is squarely against the collar.
  4.  



Click image to see an enlarged view

Fig. When installing the seal, the correct installation tool must be used

  1. Align the dowel pin of with the dowel pin hole in the crankshaft. Tighten the attaching screws to 45 inch lbs. (5 Nm).
  2.  
  3. Turn the handle of the tool until the collar is tight against the case. This will ensure the seal is fully seated.
  4.  
  5. Back the tool off and remove the attaching screws.
  6.  
  7. Install the flywheel and spacer and tighten the flywheel mounting bolts. Refer to the torque specifications chart at the end of this section.
  8.  
  9. Install the transaxle assembly.
  10.  
  11. Remove the engine support fixtures.
  12.  
  13. Connect the negative battery cable.
  14.  

 
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