what surprises am I to find, will I be able to read all timing marks with engine still in car? To see bottom timing mark on crank will I need a mirror or can this be seen? thanks..|||YOU DON%26#039;T NEED A MIRROR AND YOU DON%26#039;T NEED TO TAKE OUT THE RADIATOR. RAISE THE SIDE OF THE VEHICLE AND TAKE THE WHEEL OFF, THEN THE SPLASH SHIELD. GO IN THAT WAY. GO TO YOU SATURN DEALERSHIP, BUY THE CHAIN KIT. NOT THE CHAIN, BUT THE CHAIN KIT. IT WILL HAVE WHAT YOU NEED FOR PARTS. IF YOU DON%26#039;T GET THE KIT YOU WILL BE BACK IN IT IN A MONTH CHANGING OUT DAMPNERS. WHILE YOU ARE THERE SPENDING $$$ ASK THEM TO PRINT OUT THE PIC OF THE MARKS FOR YOU, OR COPY THEM FROM THEIR BOOK. ONLY AN IDIOT PARTS GUY WOULD SAY NO. TRUST ME HE WANTS THE SALE AND HE WOULD BE HAPPY TO DO IT FOR YOU. YOU WILL ALSO NEED A HARMONIC BALANCER PULLER TO DO THE JOB. GOOD LUCK.
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DO THIS:
Engine Front Cover Replacement (DOHC)
Tools Required
鈥? SA9103E Regulator Valve Remover/Replacer
鈥? SA9104E Front Crank Seal Replacer
Clean the front cover, cylinder block and oil pan mating surfaces:
Notice: If excessive RTV is applied, or oil builds up in the blind holes, the casting will crack when the bolts are installed. Make sure all oil gallery openings and the oil pan are covered with a shop towel to prevent debris entry.
RTV is removed from aluminum surfaces using scraper, plastic or wood, Scotch-Brite庐 Pads, and disk (3M庐 Clean-N Strip 2 in D x 1/2 in W x 1/4 in center hole).
The front cover, cylinder head and block bolt 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 3/8 in drill.
Important: Do not use petroleum cleaners such as mineral spirits, they leave a film onto which RTV will not stick.
After all RTV is removed, clean the surfaces with a chlorinated solvent, such as carburetor spray cleaner, brake clean, or alcohol.
Important: If removed, the oil pump must be packed with petroleum jelly for printing.
Install the oil pressure regulator and pump cover if removed. Install the regulator using the SA9103E and a hammer. The pump should be installed with the chamfer toward the front oil seal.
Tighten
Tighten the oil pump cover-to-front cover to 11 N路m (8 lb ft).
If the front seal was removed, use the SA9104E service tool to install a new seal. Never tap on the seal or seal installer with a hammer.
Install the new oil pressure and suction seals into their respective cavities in the cylinder block.
Important: The front cover, oil seal drain back hole, and passage way must be kept free of RTV.
Important: Extra RTV is required at oil pan, cylinder head to block, cylinder head and cam cover T-joints to make sure gaps are filled.
Apply a 4 mm (0.158 in) bead, refer to the RTV Section on the front of the oil pan and a 2 mm (0.079 in) bead on the front cover. Apply RTV around the front cover top, center bolt hole. Install the cover immediately.
Install the front crank seal using the SA9104E . The tool aligns the generator pump during front cover installation.
Install the front cover assembly fasteners.
Tighten
鈥? Tighten the front cover perimeter bolts to 30 N路m (22 lb ft).
鈥? Tighten the front cover lower center bolt (number 14) to 10 N路m (89 lb in).
Install the 4 oil pan fasteners.
Tighten
Tighten the oil pan-to-block 9 N路m (80 lb in).
Notice: 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 to prevent front seal damage.
Important: Inspect the cam cover isolators for cracks. Replace the isolators if deterioration exists.
Apply RTV across the cylinder head and front cover %26quot;T%26quot; joints, refer to %26quot;RTV%26quot; procedures in General Information. The cam cover gasket can be reused if not damaged.
Install the cam cover assembly and tighten the fasteners uniformly.
Tighten
Tighten the camshaft cover-to-head (LL0) to 10 N路m (89 lb in).
Install water pump pulley, if removed.
Tighten
Tighten the water pump pulley-to-water pump hub 25 N路m (19 lb ft).
Important: Install a thin film of RTV sealant Saturn P/N 21006236 between the 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.
Important: Hold the damper with a strap wrench or use a 3/4 in square x 12 in long piece of wood wedged between the damper spoke and rear, lower side of cover when torquing the bolt.
Install the crankshaft vibration damper/pulley assembly and retaining bolt.
Tighten
Tighten the crankshaft vibration damper/pulley-to-crankshaft to 215 N路m (159 lb ft).
Install the intake upper manifold support brace bolt located next to generator.
Tighten
Tighten the intake manifold brace-to-block (LL0) to 10 N路m (89 lb in).
Drain the engine oil and change the filter. Install the drain plug.
Tighten
Tighten the oil pan drain plug to 37 N路m (27 lb ft).
Verify the gap on all spark plugs. Install the spark plugs.
Tighten
Tighten the spark plug-to-head to 27 N路m (20 lb ft).
Important: Install the accessory drive belt idler pulley, if removed.
Install the belt tensioner.
Tighten
鈥? Tighten the belt tensioner-to-block to 30 N路m (22 lb ft).
鈥? Tighten the belt tensioner-to-front cover to 27 N路m (20 lb ft).
Install generator attachment bolts/nut (both), if removed.
Tighten
Tighten the generator bolts to 32 N路m (24 lb ft).
Install power steering pump assembly and brackets.
Tighten
鈥? Tighten the power steering pump bracket-to-block to 30 N路m (22 lb ft).
鈥? Tighten the power steering pump brace-to-block to 30 N路m (22 lb ft).
Install A/C compressor and bolts.
Tighten
鈥? Tighten the A/C compressor brackets-to-head/block to 25 N路m (19 lb ft).
鈥? Tighten the A/C compressor-to-front bracket to 54 N路m (40 lb ft).
鈥? Tighten the A/C compressor-to-rear bracket to 30 N路m (22 lb ft).
Install the accessory drive belt. Ensure that the belt is properly aligned on the pulleys.
Notice: To prevent engine front cover and mount damage, the three engine mount to engine front cover nuts must be tightened down uniformly.
Install the 2 mount to midrail bracket nuts first. Next, install the 3 front upper mount to engine front cover nuts. Remove the block of wood from under the torque strut after the upper mount assembly is installed.
Tighten
鈥? Tighten the upper engine mount-to-front cover to 50 N路m (37 lb ft).
鈥? Tighten the upper engine mount-to-front rail bracket to 50 N路m (37 lb ft).
Install splash shield and wheel.
Tighten
Tighten the wheel nuts to 140 N路m (103 lb ft).
Install the following sensors and components:
- The oxygen sensor
Tighten
Tighten the oxygen sensor to 45 N路m (33 lb ft).
- The engine coolant temperature (ECT) sensor
Tighten
Tighten the coolant temperature sensor to 8 N路m (71 lb in).
- Throttle body assembly, if removed
Tighten
Tighten the throttle body-to-air intake manifold (LL0) to 12 N路m (9 lb ft).
- The starter motor to block, if removed
Tighten
Tighten the starter motor-to-block to 37 N路m (27 lb ft).
- The starter support bracket to axle shaft, if removed
Tighten
Tighten the starter support bracket-to axle shaft bracket to 30 N路m (22 lb ft).
- The EVAP canister purge
Tighten
Tighten the canister purge solenoid-to-block to 22 N路m (16 lb ft).
- The EGR valve
Tighten
Tighten the EGR valve-to-head 25 N路m (19 lb ft).
Install the following sensors and electrical harness connectors and vacuum hoses.
Electrical Connectors:
鈥? Grounds, if disconnected
鈥? Generator
鈥? Oxygen sensor
鈥? Starter
鈥? Coolant temperature sensor
鈥? A/C compressor
鈥? Idle air control (IAC)
鈥? Throttle position (TP) sensor
鈥? EGR valve
鈥? Injectors
Vacuum Hoses:
鈥? EVAP canister purge
鈥? Throttle body
鈥? PCV
鈥? Fresh air
鈥? Brake booster
Install the accelerator cable to the bracket and attach the throttle cable. Ensure the throttle cable is properly routed and not binding.
Install the coolant hoses.
- Upper radiator
- Heater
- Deareation hose at rear side of intake manifold
Notice: Replace plastic fuel retainer whenever the fuel supply is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.
Important: The service retainers are different in color from the original equipment retainers. The service fuel feed line retainers are clear in color.
Lubricate with clean engine oil the male fuel feed line. Attach the fuel feed line and pull back to confirm engagement.
Install the fuel line clip to the intake manifold stud.
Tighten
Tighten the fuel line retainer clip to 4 N路m (35 lb in).
Install the intake manifold bracket and attach the fuel supply line.
Tighten
鈥? Tighten the support bracket-to-intake manifold (LL0) to 10 N路m (89 lb in).
鈥? Tighten the support bracket-to-intermediate shaft support bracket (LL0) to 30 N路m (22 lb ft).
Install the air intake resonator, tube, filter cover and clamps. Refer to Induction section of this service manual.
Connect the battery cables, positive cable first.
Tighten
Tighten the battery terminal bolts to 17 N路m (13 lb ft).
Install the oil pan drain plug and fill engine with new oil.
Tighten
Tighten the oil pan drain plug to 37 N路m (27 lb ft).
Install the cylinder block coolant drain plugs and close the radiator drain.
Tighten
Tighten the coolant drain-to-plug/block 30 N路m (22 lb ft).
Important: The vehicle must be level when filling with coolant.
Fill with coolant. Use only DEX-COOL鈩?ethylene glycol-based antifreeze.
Prime the fuel system.
Cycle the ignition on for 5 seconds and then off for 10 seconds.
Repeat step 31.1 twice.
Crank engine until it start, maximum starter motor cranking time is 20 seconds.
Start the engine and check for leaks.
Important: Allow the engine to idle for 3-5 minutes. If lifters are noisy or cylinders are misfiring, warm the engine up at a low RPM, less than 2,000. After the coolant temperature has reached approximately 85掳C (185掳F), cycle the engine RPM from idle to 3,000 for approximately 10 minutes or drive the vehicle 5 miles to purge the air. If the air cannot be purged, the faulty lifters will have to be replaced.
Lash adjusters that are pumped up may cause PCM misfire codes to set. Continue to operate the engine until the lash adjusters bleed down. Using the scan tool, clear codes and malfunction history.
Perform a 3 mile road test.
Fill the cooling system surge tank to the FULL COLD line and check for leaks after the engine has been tested.
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AND THIS :
Timing Chain, Sprockets, Tensioner Installation (DOHC)
Assemble the timing chain, the sprockets, the guides and the tensioners:
Verify that the crankshaft is positioned at 90 degrees past top dead center (TDC). The crankshaft keyway and sprocket must be aligned with the cylinder block main bearing cap split line, as viewed from the accessory drive end, to prevent piston and valve damage.
Notice: Do not torque the camshaft retaining bolts against the 3/16 in. timing pins as it will damage the cylinder head.
Install the camshaft timing gears, the retaining bolts and washers. The letters FRT on the sprockets must face forward, away from the cylinder head. Wrench flats 24 mm are provided to hold the camshafts from rotating while torquing the bolts.
Tighten
Tighten the camshaft sprockets-to-camshafts to 100 N路m (74 lb ft).
Bring the camshafts up to the number one TDC by rotating the camshaft and sprocket until the timing pins 4.77 mm (3/16 in) drill can be installed. Wrench flats are installed on the camshafts to assist with rotation.
Rotate the crankshaft counterclockwise, as viewed from the accessory drive end, until the number one cylinder is TDC. The crankshaft sprocket timing mark will align with cylinder block timing mark.
Caution: The camshaft can rotate during timing chain installation when the timing pins (4.77 mm (3/16 in) drill) have not been installed. Do not place fingers between the camshaft sprockets and the chain during the timing chain installation.
Place the timing chain over the camshaft sprockets and under the crankshaft sprocket.
Notice: Excess slack in the chain must be kept to the chain tensioner side (movable guide) of the cylinder block when installing the timing chain or the camshaft sprockets will not be correctly timed to the crankshaft sprocket.
Important: Two separated black link plates align the pip marks on the camshaft sprockets and another 2 paired link plates align the crankshaft sprocket tooth that is located at the six o%26#039;clock position. The pip mark on the crankshaft sprocket must be aligned with the timing mark on the cylinder block.
Important: Alignment of both timing pin holes, crankshaft sprocket pip mark with cylinder block mark, black links with camshaft and crankshaft sprockets must be correct to make sure the engine is properly timed.
Ensure that the black colored link plates are located over the pip mark on the cam sprockets only. The crankshaft sprocket tooth must be pointed directly downward at the 6 o%26#039;clock position between the 2 silver colored links. The pip mark on the crankshaft sprocket will be aligned with the timing mark on the cylinder block.
Important: The timing chain should be snug against the fixed guide.
Install the fixed guide.
Tighten
Tighten the timing chain fixed guide-to-block to 26 N路m (19 lb ft).
Install the pivoting chain guide. Inspect for clearance between the block and the head. Torque the bolt and ensure the guide pivots freely.
Tighten
Tighten the timing chain pivot guide-to-head to 26 N路m (19 lb ft).
Important: The camshafts must be positioned fully forward prior to bearing cap installation.
Install the 2 forward remaining camshaft bearing caps and timing chain guide.
Tighten
Tighten the camshaft bearing cap-to-head (LL0) to 14 N路m (10 lbs ft).
Retract the tensioner plunger and pin the ratchet lever using a 3.18 mm (1/8 in) or No 31 drill. Install the chain tension and torque the 2 bolts. Remove the drill and allow the tensioner plunger to extend.
Tighten
Tighten the timing chain tensioner-to-block to 19 N路m (14 lb ft).
Verify all timing marks for accuracy. Remove the camshaft timing pins.
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SORRY THE PICS DIDN%26#039;T PASTE.|||yes you can but why you don%26#039;t replace your timing chain in dealer|||dont attempt this without a manual. usually you need to remove the grill and radiator/intercooler. also any fans or pulleys in the way. you will need a timing light and your manual will tell you how to determine TDC. (TOP DEAD CENTER) everything gets dialed in from there, good luck
