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Home >> Saturn >> 2006 >> Relay 3.9 1, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Mechanical - 3.5L) >> Repair Instructions - Off Vehicle >> Engine Block Assemble

Engine Block Assemble

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Locating Engine Oil Pressure Indicator Switch
    GM909630Courtesy of GENERAL MOTORS CORP.
  1. Apply sealer P/N 21485278, or equivalent to the oil pressure switch threads.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the engine oil pressure switch.

    Tighten:  Tighten the engine oil pressure switch to 16 N.m (12 lb ft).

    3. Fig 2: View Of Knock Sensors
    GM909629Courtesy of GENERAL MOTORS CORP.
  3. Install the knock sensors.

    Tighten:  Tighten the knock sensors to 25 N.m (18 lb ft).

    4. Fig 3: Installing Engine Block Plug
    GM909628Courtesy of GENERAL MOTORS CORP.
  4. Apply sealer P/N 21485278, or equivalent to the engine block plug or engine block heater, if applicable.
  5. Install the engine block plug or engine block heater, if applicable.

    Tighten:  Tighten the engine block plug or engine block heater to 60 N.m (44 lb ft).

  6. Install the transmission locating pins. The installation height should be 8.3-9.3 mm (0.327-0.366 in) (A).
    7. Fig 4: Removing/Installation Front Oil Gallery Plugs (107, 110, 137)
    GM909627Courtesy of GENERAL MOTORS CORP.
  7. Apply sealer P/N 21485278, or equivalent to the front oil gallery plug threads (110, 137).
  8. Install the front oil gallery plug (110).

    Tighten:  Tighten the front oil gallery plug to 19 N.m (14 lb ft).

  9. Install the front oil gallery plug (137).

    Tighten:  Tighten the front oil gallery plug to 33 N.m (24 lb ft).

  10. Apply sealer P/N 12377901, or equivalent to the front oil gallery plug (107).
  11. Install the front oil gallery plug (107) so that it is 1.5 mm (0.06 in) below flush of the engine block.
  12. Install the engine front cover locating pins (546). The installation height should be 5.8-8.2 mm (0.228-0.323 in) (A).
    13. Fig 5: Removing/Installation Rear Oil Gallery Plugs (102, 103)
    GM909626Courtesy of GENERAL MOTORS CORP.
  13. Apply Sealer P/N 21485278, or equivalent to the rear oil gallery plugs.
  14. Install the rear oil gallery plugs (103).

    Tighten:  Tighten the rear oil gallery plugs to 19 N.m (14 lb ft).

  15. Install the rear oil gallery plugs (102).

    Tighten:  Tighten the rear oil gallery plugs to 33 N.m (24 lb ft).

    16. Fig 6: Removing/Installing Coolant Drain Plug From Left Side
    GM909514Courtesy of GENERAL MOTORS CORP.
    NOTE: Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.
  16. Apply sealer P/N 21485278, or equivalent to the left and right coolant drain plug threads.
  17. Install the left coolant drain plug.

    Tighten:  Tighten the left coolant drain plug to 19 N.m (14 lb ft).

    18. Fig 7: Removing/Installing Coolant Drain Plug From Right Side
    GM909516Courtesy of GENERAL MOTORS CORP.
  18. Install the right coolant drain plug.

    Tighten:  Tighten the right coolant drain plug to 19 N.m (14 lb ft).

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