Oil Pump And Front Cover Installation

TOOLS REQUIRED:  SA9104E Front Crank Seal Replacer

Torque: 

Torque Axis Mount Studs: 10 N.m (89 in-lbs) 

Fig 1: Axis Mount Studs

Courtesy of GENERAL MOTORS CORP.

1. Clean the front cover and cylinder block mating surfaces:
   NOTE: 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.
   1. RTV is removed from aluminum surfaces using scraper, plastic or wood, Scotch-Brite(R) Pads, and disk (3M(R) Clean' N Strip 2 in. D x 1/2 in. W x 1/4 in. center hole).
      NOTE: Do not use petroleum cleaners such as mineral spirits; they leave a film onto which RTV will not stick.
   2. 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.
   3. 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).
      Fig 2: Cleaning RTV

      Courtesy of GENERAL MOTORS CORP.
   NOTE: The oil pump must be packed with petroleum jelly if removed.
2. Install oil pressure regulator, oil pump and pump cover if removed. Use Saturn P/N 21485277 (Loctite(R) 242 Threadlocker or equivalent) on the oil pump cover screws.

   Torque: 

   Oil Pump Cover-to-Front Cover: 11 N.m (8 ft-lbs) 

   Fig 3: Installing Oil Pressure Regulator

   Courtesy of GENERAL MOTORS CORP.
3. If front seal was removed, use Front Crank Seal Replacer SA9104E to install a new seal.
4. Install new oil pressure and suction seals into their respective cavities in the cylinder block.
   Fig 4: Installing New Oil Pressure And Suction Seals

   Courtesy of GENERAL MOTORS CORP.
   NOTE: Extra RTV is required at oil pan, cylinder head to block, cylinder head and cam/rocker cover T-joints to make sure gaps are filled. A RTV bead around the top center bolt hole is required.
5. Apply a 4.0 mm (0.157 in.) bead on the front of the oil pan and a 2.0 mm (0.079 in.) bead on the front cover as shown. Install cover immediately. Parts must be assembled within three minutes of application or the material must be removed and applied again.
   Fig 5: Applying Sealant To RTV

   Courtesy of GENERAL MOTORS CORP.
   NOTE: The front cover oil seal drain back hole and passage way must be kept free of RTV.
   NOTE: The Front Crank Seal Replacer SA9104E is used to align the gerotor oil pump during front cover installation.
6. Install front cover assembly and bolts.
7. Install the four front cover oil pan fasteners.

   Torque: 

   Front Cover Perimeter Bolts: 30 N.m (22 ft-lbs) 

   Torque: 

   Front Cover Lower Center Bolt (Number 14): 10 N.m (89 in-lbs) 

   Torque: 

   Oil Pan-to-Block: 9 N.m (80 in-lbs) 

   Fig 6: Front Cover Bolts

   Courtesy of GENERAL MOTORS CORP.
   NOTE: 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.
   NOTE: 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.
   Fig 7: Apply A Thin Film Of RTV Sealant

   Courtesy of GENERAL MOTORS CORP.
   NOTE: 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 cover when torquing bolt.
8. Install a new Front Crank Seal Replacer SA9104E. Install the vibration damper/pulley assembly and retaining bolt/washer. Never tap on the seal or seal installer with a hammer.

   Torque: 

   Crankshaft Vibration Damper/Pulley-to-Crankshaft: 215 N.m (159 ft-lbs) 

   Fig 8: Install The Vibration Damper/Pulley Assembly

   Courtesy of GENERAL MOTORS CORP.
9. Apply RTV across the cylinder head and front cover T-joints.
   Fig 9: Applying RTV Across The Cylinder Head

   Courtesy of GENERAL MOTORS CORP.
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.

    Torque: 

    Belt Tensioner-to-Block: 30 N.m (22 ft-lbs) 

13. Install power steering pump.
14. Install the accessory drive belt. Make sure belt is properly aligned on pulleys.
    NOTE: To prevent engine front cover and mount damage, the three engine mount to engine front cover nuts must be tightened down uniformly.
15. Install the two engine mount to midrail bracket nuts first. Next, install the three engine mount to engine front cover nuts. Remove the block of wood from under the torque strut after the upper mount assembly is installed.
    Fig 10: Engine Mount To Midrail Bracket Nuts

    Courtesy of GENERAL MOTORS CORP.

    Torque: 

    Engine Mount-to-Front Cover Nuts: 50 N.m (37 ft-lbs) 

    Torque: 

    Engine Mount-to-Midrail Bracket Nuts: 50 N.m (37 ft-lbs) 

16. Install splash shield and wheel.

    Torque: 

    Wheel Nuts: 140 N.m (103 ft-lbs) 

17. Drain engine oil and change filter. Install drain plug.

    Torque: 

    Oil Pan Drain Plug: 37 N.m (27 ft-lbs) 

18. Install the battery cables, positive cable first.

    Torque: 

    Battery Terminal Bolts: 17 N.m (13 ft-lbs) 

19. Fill with new engine oil (API 5W30 Energy Conserving II multigrade viscosity oil).
20. Reset CHANGE OIL SOON telltale lamp. Refer to RESETTING CHANGE OIL SOON TELLTALE LAMP  .
21. Start engine and check for leaks.
22. Check the engine oil level and fill if necessary.
23. Perform a road test.
24. Check coolant and oil levels. Verify there are no leaks.