JustAnswer
Hello and thank you for your post. I am a master certified GM tech, with 15 years Saturn experience,and can help you to resolve your issue..
I believe what you want are step by step instructions on how to do this entire job, including diagrams of each component you have to remove.
I will send you anything I can think of that will help you.
|CYLINDER HEAD REPLACEMENT FRONT |
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|TOOLS REQUIRED |
|SA9105E Three Bar Engine Support Tool |
|SA9140E Torque Angle Gauge |
|REMOVAL |
|Disconnect negative battery cable. |
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|Remove intake manifold and spacer. |
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|Drain coolant. |
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|Remove coolant bridge bolts. |
|Remove coolant bridge seals. |
|Remove upper radiator hose from coolant pipe. |
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|Remove oil level indicator tube and coolant pipe tube bolt. |
|Remove oil level indicator tube by pulling upwards. |
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|Twist coolant pipe to remove front thermostat housing. |
|Remove engine lift bracket. |
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|Remove front camshaft cover. |
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|Remove ECM from ECU bracket. |
|Remove electrical grounds from cylinder head |
|Disconnect oxygen sensor electrical connection. |
|Disconnect oxygen sensor harness from bracket. |
|Remove rear engine lift bracket. CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE 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. |
|Raise vehicle. |
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|Remove front exhaust manifold down pipe. |
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|Remove timing belt. |
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|Remove rear timing belt cover. |
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|IMPORTANT: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E". |
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|NOTICE: It is not necessary to remove intake camshaft for head bolt access. |
|Remove exhaust camshaft. |
|Install floor jack with a block of wood under oil pan and support engine. |
|Remove Three Bar Engine Support Tool SA9105F. |
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|Loosen cylinder head bolts in sequence shown. |
|Remove cylinder head bolts. |
|Remove cylinder head. |
|Clean and inspect cylinder head and sealing surfaces. |
|Disassemble cylinder head and service necessary. |
|INSTALLATION |
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|With cylinder head assembled (except exhaust camshaft) install exhaust manifold and new gasket. Torque: Exhaust Manifold Nut: 20 Nm (15 ft.|
|lbs.) |
|Install new cylinder head gasket with part number imprint toward the top of engine. |
|Install cylinder head to engine block ensuring adequate clearance from all wires, components, etc. |
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|IMPORTANT: Use new cylinder head bolts. The required tightening method stretches the bolts to their yield point, Therefore, the cylinder |
|head bolts are not reusable. |
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|NOTICE: Use Torque Angle Gauge SA9140E (or equivalent) and the proper tightening sequence to tighten cylinder head bolts in stages. |
|Install new cylinder head bolts. Torque: Cylinder Head Bolt: 25 Nm (18 ft. lbs.) + 90 degrees + 90 degrees + 90 degrees + 15 degrees |
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|Replace the two sealing rings on coolant pipe if pipe was remove earlier. |
|Lubricate the two sealing rings with coolant. |
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|Properly position engine lift bracket. |
|Install coolant pipe into position and fully seat pipe into housing if removed earlier. |
|Install oil level indicator tube. |
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|Install coolant pipe and engine lift bracket bolt to cylinder head. Ensure that bolt passes through all attached components. Torque: |
|Coolant Pipe/Engine Lift Bracket Bolt: 20 Nm (15 ft. lbs.) |
|Install Three Bar Engine Support Fixture to 6 Cylinder (1,81) B. |
|Remove floor jack with block of wood. |
|Install upper radiator hose to coolant pipe. |
|Install upper radiator hose clamp. |
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|IMPORTANT: The intake camshaft is marked with the letter "A" and the exhaust camshaft is marked with the letter "E" |
|Install exhaust camshaft. |
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|Install rear timing belt cover. |
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|Install front timing belt cover. |
|Remove Three Bar Engine Support Fixture. |
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|Install front camshaft cover. |
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|Properly position coolant bridge seals on block. |
|Install coolant bridge into position. |
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|Install coolant bridge bolts. Torque: Coolant Bridge Bolt: 30 Nm (22 ft. lbs.) |
|Install intake manifold spacer and tighten bolts in sequence. Torque: Intake Manifold Spacer-to-Cylinder Head Bolt: 16 Nm (11 ft. lbs.) |
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|Install intake manifold. |
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|Refill coolant. |
|Connect negative battery cable. Torque: Battery Terminal Bolt: 17 Nm (13 ft. lbs.) |
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|Removal Procedure |
|Remove the front timing belt cover. |
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|Rotate the crankshaft using the J 42098 until the #1 cylinder is at 60 degrees before top dead center (BTDC). |
|Install the J 42069 Crankshaft Locking Tool. |
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|Rotate the crankshaft in the engine rotational direction (clockwise) using the J 42098 until the #1 cylinder is at top dead center (TDC) |
|and tighten the lever arm to the water pump pulley flange. Important: Ensure that the alignment of the crankshaft is not 180 degrees off. |
|The alignment mark must align with the corresponding notches on the rear timing belt cover. |
|Install the 1-2 and 3-4 camshaft locks, the J42069-1 Timing Belt Alignment Kit and the J42069-2. Important: Do not rotate the crankshaft if|
|the camshafts are not locked in place with the 1-2 and 3-4 camshaft locks (J42069-1 and J42069-2). Do not rotate the camshafts unless the |
|crankshaft is at 60 degrees BTDC or the valves may contact the crankshaft. |
|Loosen the tensioner pulley. |
|Remove the timing belt. |
|Installation Procedure |
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|Position crank at 60 degrees before TDC. Notice: Refer to Fastener Notice in Cautions and Notices. |
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|Install the lower idler pulley. Tighten the lower idler pulley bolt to 40 Nm (30 ft. lbs.) |
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|Install the upper idler pulley and hand tighten bolt. |
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|Important: With the camshaft locks installed, verify the distance between the camshaft sprockets with the Green Test Belt located in the |
|Timing Belt Alignment Kit J 42069. |
|Install the timing belt tensioner and hand tighten nut and washer. |
|Start #1 and #2 camshaft sprockets, route belt around #1 and #2 sprockets while aligning belt marks to marks on the sprocket and rear |
|cover. |
|Install the belt around the timing belt tensioner. |
|Route belt around upper idler pulley. |
|Route belt around #3 and #4 camshaft sprockets while aligning belt marks to marks on sprockets and rear cover. |
|Route belt around crankshaft hub sprockets while aligning marks on belt to marks on the crankshaft hub sprocket. |
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|Install the wedge tool J 42069-30 to lock the timing belt onto crankshaft hub sprocket. |
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|With belt firmly engaged on crankshaft hub, carefully rotate the crankshaft counterclockwise to get belt slack on lower idler pulley side. |
|Route belt around the lower idler pulley. |
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|Remove the wedge tool J 42069-30. |
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|Re-install the crankshaft locking tool J 42069-10 and tighten the lever arm to the water pump pulley flange. |
|Perform the following in sequence: |
|Install the camshaft checking gage to cams 3 and 4 and verify alignment marks are within 2 mm of each other. |
|Install 3 and 4 camshaft locks if properly aligned. |
|Install camshaft checking gage to cams 1 and 2. |
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|Rotate #1 camshaft sprocket counterclockwise to remove slack between 1 and 2, and 3 and 4 cams. |
|Important: Ensure that the camshaft timing marks are to the left (retard) side of the checking gage. |
|Rotate the upper idler pulley counterclockwise until the marks are properly aligned within 2 mm of each other. |
|Install 1 and 2 camshaft locks when properly aligned. Tighten the idler pulley bolt to 40 Nm (30 ft. lbs.) |
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|Adjust the timing belt tensioner that the center alignment mark is approximately 3mm (1/8 inch) above the alignment on the spring loaded |
|idler. |
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|Remove the 1 and 2 and 3 and 4 camshaft locks. |
|Remove the timing belt kit J 42069-1 and J 42069-2. |
|Remove the crankshaft locking tool J 42069-10. Important: If the TDC is passed, do not rotate the crankshaft counterclockwise. This will |
|not allow proper slack to be taken up between the timing belt tensioner and crankshaft sprocket. To correct, rotate the crankshaft two |
|additional turns. |
|Rotate the crankshaft 1 3/4 turns clockwise, install the crankshaft locking tool J 42069-10, and stop at TDC. |
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|Tighten lever arm to the water pump pulley flange. |
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|Install the checking gage J 42069-20 and verify the marks are 2 mm of each other. |
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|Adjust the timing belt tensioner that the center alignment mark is approximately 3 mm above the alignment mark on the spring loaded idler |
|and tighten the timing belt tensioner nut. Tighten the timing belt tensioner nut to 20 Nm (15 ft. lbs.) |
|Remove the crankshaft locking tool J 42069-10 and the checking gage J 42069-20. |
|Install the front timing belt cover. |
|Lower the vehicle. |
|Install the air cleaner assembly. |
|Connect the negative battery cable. Tighten the battery terminal bolt to 17 Nm (13 ft. lbs.) |
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