Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Timing Chain Cover

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REMOVAL & INSTALLATION



See Figures 1 through 21

  1. Disconnect the negative battery cable, then raise and support the front of the vehicle sufficiently to work both under the vehicle and under the hood. Be sure to properly position the jackstands.
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  3. Remove the plug from the oil pan and drain the engine oil into a suitable container. Remove the right wheel and splash shield.
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  5. For 1992-98 vehicles with a torque axis mount system, place a 1 in. x 1 in. x 2 in. long block of wood between the torque strut and cradle to ease removal and installation of the torque engine mount. Remove the 3 right side upper engine torque axis to front cover nuts and the 2 mount to midrail bracket nuts, allowing the powertrain to rest on the block of wood.
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Placing a block of wood under the torque axis mount prior to removing the upper mount will allow the engine to rest on the wood, thus preventing the engine from shifting. This will allow you to install the mount during assembly without jacking or raising the engine.

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Fig. Fig. 1: Place a 1 in. x 1 in. x 2 in. long piece of wood between the torque strut and cradle before removal of the torque engine mount



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Fig. Fig. 2: Loosen the torque engine mount-to-cylinder head retaining bolts ...



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Fig. Fig. 3: ... then loosen the torque engine mount-to-body retaining bolts



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Fig. Fig. 4: Remove the torque engine mount from the engine

  1. Remove the serpentine drive belt and belt tensioner. It is not necessary to remove the water pump pulley; however, for 1992-98 vehicles the idler pulley must be removed to access the engine front cover.
  2.  
  3. Remove the power steering pump attaching bolts and support the assembly aside with the lines attached. If equipped, and if necessary for access to the front cover bolts, separate the A/C compressor from the bracket and support the assembly aside. Again, keep the compressor lines attached and do not discharge the system.
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  5. Remove the camshaft cover. Cover the valve train assemblies to protect them from foreign debris or dirt.
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  7. Using a strap wrench or a piece of wood wedged between the damper spoke and the lower side of the engine front cover, hold the damper and remove the bolt. With a suitable 3-jaw puller and the slots cast into the damper, pull the crankshaft damper/pulley assembly from the crankshaft.
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Fig. Fig. 5: Loosen the belt tension idler pulley bolt ...



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Fig. Fig. 6: ... and remove the pulley



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Fig. Fig. 7: Loosen the serpentine belt tensioner mounting bolts ...



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Fig. Fig. 8: ... and remove the belt tensioner from the vehicle



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Fig. Fig. 9: With the refrigerant lines still attached, unfasten the A/C compressor and support the assembly aside



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Fig. Fig. 10: Remove the camshaft cover. Place a cover over the valve train assembly to protect it from dirt and debris



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Fig. Fig. 11: After wedging a piece of wood between the damper spoke and lower side of the engine front cover, loosen ...



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Fig. Fig. 12: ... then remove the damper pulley retaining bolt



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Fig. Fig. 13: Remove the damper pulley from the crankshaft stub

  1. Install the special oil seal replacement tool SA9104E or equivalent, to make sure the front crankshaft timing sprocket is held firmly in place and prevent guide damage. Install with the flat side towards the crankshaft sprocket.
  2.  
  3. Remove the front 4 oil pan bolts, then using a suitable RTV cutting tool, cut the front seal away from the front cover.
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  5. Spray the 2 dowel pin holes with penetrating oil to facilitate front cover removal from the dowel pins.
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  7. Remove the front cover bolts. For 1992-98 vehicles, one bolt is located above the serpentine drive belt pulley, under the torque axis mount flange.
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  9. Using a small suitable tool, carefully pry the cover away from the cylinder block at the pry location tabs which are provided. Remove the cover from under the hood or through the wheel well. Be sure to cover the front of the engine to prevent debris or dirt from entering the oil galley openings and oil pan. If necessary, pry the front cover oil seal from the cover for replacement.
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To install:
  1. Make sure the oil galleys are clear. Carefully clean the gasket mating surfaces with a scraper or wire brush and carburetor solvent, brake clean or alcohol. Use a 3 / 16 in. drill bit and tap handle to clean the front cover holes. If removed, seat a new front cover oil seal using the installation tool with a suitable press, or wait until the cover is installed, then use a threaded installation tool and the crankshaft's threads to pull the seal into position. For additional details, refer to the Timing Chain Cover Oil Seal replacement procedure, later in this section.
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Fig. Fig. 14: Install a special tool to hold the crankshaft timing sprocket firmly in place



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Fig. Fig. 15: Remove the 4 oil pan-to-timing cover bolts ...



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Fig. Fig. 16: ... then, with a suitable RTV cutting tool, cut away the front seal



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Fig. Fig. 17: Spray the 2 dowel pin holes with penetrating oil to facilitate front cover removal



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Fig. Fig. 18: Remove the timing cover mounting fasteners



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Fig. Fig. 19: Lift the timing chain front cover up and out of the vehicle

If the engine front cover casting or assembly is replaced on 1992-98 vehicles, the 3 torque axis mount studs should also be replaced. Tighten the new studs to 19 ft. lbs. (25 Nm).

  1. Apply a 0.08 in. (2mm) bead of RTV sealer along the vertical sealing surfaces of the front cover to the inside of the bolt holes and to the front of the oil pan. Extra sealer is necessary at the oil pan and cylinder head joints. For DOHC engines, apply a thin bead around the one center cover bolt hole on 1991 vehicles or the 2 inner cover bolt holes on 1992-98 vehicles. Be sure to assemble the front cover to the engine within 3 minutes of RTV application.
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  3. If removed, install the crankshaft sprocket retaining tool to align the oil pump and crankshaft during cover installation. Position the front cover to the engine and install the bolts. Tighten the perimeter bolts starting at the center and working outwards on both sides to 19 ft. lbs. (25 Nm) for SOHC engines or to 22 ft. lbs. (30 Nm) for DOHC engines.
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  5. Install and tighten the front cover center or inner bolts to 89 inch lbs. (10 Nm) except for the upper inside bolt on 1992-98 DOHC engines which should be tightened to 22 ft. lbs. (30 Nm). Install the 4 oil pan front bolts and tighten to 80 inch lbs. (9 Nm).
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  7. After front cover installation, spray 6-12 squirts of oil through the front oil seal drain back hole to verify that it is not plugged.
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  9. Apply a thin film of RTV between the damper/pulley assembly flange and washer only; the washer and bolt head flange are designed to prevent oil leakage.
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  11. Remove the crankshaft retaining tool and position the crankshaft damper/pulley assembly, then secure using the wood or strap wrench (as accomplished during removal) and tighten the bolt to 159 ft. lbs. (215 Nm).
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  13. Apply a small drop of RTV across the cylinder head and front cover T-joints. Inspect the old camshaft cover gasket and replace if damaged. Install the gasket and the camshaft cover. Tighten the fasteners uniformly to 22 ft. lbs. (30 Nm) for SOHC vehicles or in proper sequence to 89 inch lbs. (10 Nm) for DOHC vehicles.
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  15. Position and install the A/C compressor assembly and/or the power steering pump assembly, as applicable.
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  17. Install the idler pulley if removed, then install the belt tensioner and the serpentine drive belt.
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  19. For 1992-98 vehicles equipped with a torque axis mount system, install the 2 engine mounts to midrail bracket nuts and tighten to 37 ft. lbs. (50 Nm). Next install the 3 mount to front cover nuts, tighten them uniformly to 37 ft. lbs. (50 Nm) in order to prevent front cover damage. Then, remove the block of wood from under the torque strut.
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  21. Install the splash shield and the wheel assembly, then remove the jackstands and carefully lower the vehicle.
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  23. Immediately fill the engine crankcase with clean engine oil and connect the negative battery cable.
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  25. Start the engine and check for leaks.
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Fig. Fig. 20: Apply a thin bead of RTV sealer as shown-SOHC engine



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Fig. Fig. 21: Apply a thin bead of RTV sealer as shown-DOHC engine

 
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