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Home >> Saturn >> 2000 >> SL L4-1.9L SOHC VIN 8 >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Timing Components >> Timing Cover >> Service and Repair >> Front Cover and Oil Pump Removal

Front Cover and Oil Pump Removal

- Tools Required
- SA9123E Gasket Seal Cutter
- SA9104E Front Crank Seal Replacer

CAUTION: MAKE SURE THE VEHICLE IS SECURELY SUPPORTED BEFORE LIFTING ON A HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. MAKE SURE THE HOIST DOES NOT CONTACT FUEL OR BRAKE LINES.

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1. Disconnect negative battery cable.
2. Jack vehicle, or raise vehicle on a hoist.
3. Drain engine oil.

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4. Remove the right wheel and splash shield.

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5. Place a 1 inch x 1 inch x 2 inch long block of wood between the torque strut and cradle.

IMPORTANT: Installation of the wood block prior to upper engine torque axis mount removal allows the mount to be easily installed without lifting or jacking the powertrain.

6. Remove engine accessory drive belt.

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7. Remove front crankshaft vibration damper/pulley assembly. Hold damper with a strap wrench when removing bolt.

IMPORTANT: The crankshaft vibration damper/pulley bolt head and washer prevents oil leakage from the cavity around the end of crankshaft.

Puller jaw slots are cast into the damper/ pulley assembly for removal with a small three-jaw puller, if required.

IMPORTANT:
- Do not pry against the cover.
- The accessory drive belt idler pulley must be removed to allow the front cover to be removed and replaced in the vehicle.

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8. Remove the power steering pump assembly and position it on the intake manifold.

IMPORTANT: It is not necessary to remove the power steering pump for access to the bracket attachment bolts. The DOHC (LL0) engine has an additional bracket located under the pump and the attachment bolt can be accessed through an oval hole in the pump's pulley.

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9. Remove the belt tensioner.
10. Remove the cam cover (DOHC [LL0]) engine.

IMPORTANT: Cover camshaft area whenever repairs are not being performed to prevent foreign debris from entering engine.

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11. Remove the three right-hand engine mount to front cover nuts and the two engine mount to midrail bracket nuts, allowing the powertrain to rest on the block of wood.

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12. Removal of front cover assembly:

NOTICE: Failure to hold the crankshaft timing sprocket in place will cause timing chain guide damage. The tool also aligns the gerotor during front cover installation. After the front cover assembly is loosened and moved approximately 25.4 mm (1 inch) from the engine, the crankshaft timing gear service tool should be removed.

Install the crankshaft timing gear service tool SA9104E to make sure the front crankshaft timing sprocket is held firmly in place.

IMPORTANT: Install the service tool SA9104E with the flat side towards the crankshaft sprocket.

NOTICE: Spray the two dowel pin holes in the front cover with penetrating oil to facilitate cover removal off the dowel pins.

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13. Remove the four front oil pan bolts and 14 front cover bolts:
a. Use RTV cutter service tool SA9123E to cut the oil pan seal away from the front cover.

NOTICE: On (DOHC [LL0] ) engines, one front cover assembly attachment bolt is located under the torque axis mount flange, above the accessory drive belt idler pulley.

IMPORTANT: After the front cover assembly is loosened and moved approximately 25.4 mm (1 inch) from the engine, the crankshaft timing gear service tool should be removed.

b. Remove the front cover bolts.

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14. Using the front cover pry tangs, remove the front cover from the cylinder block:
a. Remove the two oil gallery transfer seals and discard.

IMPORTANT: The front cover assembly can be removed from under the hood or through the wheel well.

15. Place shop towels over the front of engine and oil pan opening to prevent debris entry.

IMPORTANT: To facilitate front cover installation, install the front cover without RTV applied and position into place. Then remove the cover for RTV application and final installation. This will help prevent RTV disturbance on final installation.

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