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HOMESERVICE MANUALSSATURN2000SW2 AUTOMATICREPAIR AND DIAGNOSISENGINE MECHANICALMECHANICAL1.9L 4-CYLINDERREMOVAL & INSTALLATIONFRONT COVER & TIMING CHAININSTALLATION
2000 Saturn SW2 Automatic

Front Cover & Timing Chain: Installation

2000 Saturn SW2 AutomaticSECTION Installation
  1. To prevent pistons from hitting valves, ensure timing mark and keyway on crankshaft are aligned with split line of main bearing cap. Install camshaft sprocket(s) with letters FRT (front) facing away from cylinder head.
  2. Rotate camshaft until a 3/16" (4.8 mm) drill bit can be inserted through pin hole and into cylinder head. See Fig 1 or Fig 2 . Use a 7/8" (21 mm) wrench to keep camshaft(s) from turning. Install and tighten camshaft sprocket bolt(s) to specification. Rotate crankshaft(s) counterclockwise as viewed from front of engine until timing marks at crankshaft sprocket are aligned. Install timing chain, aligning Silver-plated chain links with marks on sprockets. See Fig 1 or Fig 2 .
  3. Install fixed chain guide. Slack part of chain should be on tensioner side of cylinder block. Chain should be tight against fixed chain guide. Install pivoting chain guide. Retract tensioner plunger, and insert a 1/8" or No. 31 (3.2 mm) drill bit into lever locking hole. Install tensioner.
  4. Check timing mark alignment. Remove drill bits from camshaft sprockets and tensioner. If oil pump and pressure regulator were removed from front cover, install them using special procedures. See OIL PUMP  under ENGINE OILING. If front seal was removed, press NEW seal into front cover using Seal Installer (SA9104E).
    CAUTION: DO NOT allow RTV sealant to clog oil passage holes, including drain-back hole at bottom of oil seal.
  5. Install NEW oil pressure seal (pump outlet) and suction seal (pump inlet) into cavities in cylinder block. Apply a .16" (4 mm) bead of RTV sealant onto oil pan sealing surface. Apply a .08" (2 mm) bead of RTV sealant onto front cover sealing surface. Apply RTV sealant to bolt hole in middle of cover above oil pump (and top center of front cover on DOHC). Apply extra RTV sealant onto joint where head meets block. Install front cover immediately.
  6. Install Crankshaft Gear Retainer (SA9104E) to align oil pump drive gear. Tighten front cover bolts in sequence to specification. See Fig 3 or Fig 4. See TORQUE SPECIFICATIONS .
    NOTE: After front cover is installed, 6-12 squirts of oil should be pumped through front seal drain back hole to ensure it is not plugged.
  7. Install cylinder head cover. If silicone isolators are deteriorated, replace as necessary. Tighten cylinder head cover bolts to specification (start at center and work outward). To complete installation, reverse removal procedure.
Fig 1: Installing Timing Chain (SOHC)
G98H07019Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.