1997 Saturn SL1 head gasket

REMOVAL:
Disconnect the negative battery cable and remove the coolant bottle cap. Drain the engine coolant from the radiator and block drains into a suitable clean container.
Remove the air cleaner/inlet duct assembly. Disconnect the PCV valve and fresh air hose from the camshaft cover.
Disconnect the accelerator cable from the throttle body and the bracket from the intake manifold.
Properly relieve the fuel system pressure.
Label and disconnect the following electrical connectors from the cylinder head assembly and components, as applicable. Long nose pliers are necessary to disconnect the coolant temperature connectors. When disconnected, position the electrical harness over the underhood junction block and battery cover.
Coolant temperature and PCM connectors. These connectors are located on the rear side of the cylinder head for DOHC engines.
The single injector connector (TBI Engine) or the 4 injector connectors (MFI Engine).
Idle Air Control (IAC) valve.
Manifold Air Pressure (MAP) sensor.
Throttle Position Sensor (TPS).
Exhaust Gas Recirculation (EGR) solenoid.
Label and disconnect the spark plug wires from the plugs.
Oxygen sensor.
Air conditioning compressor.
Label and disconnect the following vacuum hoses, as applicable, from the area around the cylinder head assembly.
Canister purge valve.
EGR valve.
MAP sensor, for the 1991-94 SOHC engine only.
Brake booster vacuum hose at the intake manifold or the brake booster.
Throttle Body Injection (TBI) unit assembly on 1991-94 SOHC Engines or the throttle body for all MFI engines.
Fuel regulator, for 1991-97 DOHC or 1995-97 SOHC engines.
Disconnect the upper radiator hose at the cylinder head outlet, the de-aeration hose at the intake manifold, or the heater hose at the intake manifold or front of dash.
Remove the bolt which retains the fuel lines to the intake manifold assembly. Disconnect the fuel feed and return lines from the fuel rail or throttle body, as applicable.
For 1992-98 vehicles with a torque axis mount system, unclip the lower splash shield for access. Place a 1 in. X 1 in. X 2 in. Long block of wood between the torque strut and cradle to ease removal and installation of the torque engine mount. Remove the 3 right side upper engine torque axis to front cover nuts and the 2 mount to midrail bracket nuts, allowing the powertrain to rest on the block of wood.
Placing a block of wood under the torque axis mount prior to removing the upper mount will allow the engine to rest on the wood, thus preventing the engine from shifting. This will allow you to install the mount during assembly without jacking or raising the engine.

Remove the serpentine drive belt and belt tensioner. It is not necessary to remove the water pump pulley, however, for 1992-98 vehicles it will be necessary to remove the idler pulley to access the engine front cover.
For SOHC engines, disconnect the de-aeration line at the cylinder head water outlet and from the support bracket.
Remove the fasteners and the camshaft cover, then inspect the cover's silicone insulators for cracks or deterioration and replace as necessary. Be sure to cover the valve train area to prevent dirt and debris from entering the engine.
Remove the power steering pump bracket attaching bolts (3 for the SOHC engine or 5 for the DOHC engine) and position the assembly next to the right side front of the dash panel away from the intake manifold and cylinder head. It is not necessary to remove the water pump pulley.
If equipped, remove the 3 air conditioning compressor front bracket bolts attached to the cylinder head and block, then remove the rear bracket bolts from the compressor or engine. Do not discharge the system or disconnect the refrigerant lines. Support the compressor out of the way, from the vehicle front support bar.
Raise and support the front of the vehicle safely using jackstands.
Drain the engine oil into a suitable drainpan.
Remove the right side tire and splash shield.
For DOHC engines, remove the intake manifold support brace bolt attached to the intake manifold next to the alternator.
Remove the crankshaft damper/pulley assembly. Use a strap wrench or a block of wood wedged between the pulley spoke and the rear lower side of the front cover to hold the assembly while removing the bolt. Then use a 3-jaw puller on the jaw slots cast into the pulley to remove the assembly.
Disconnect the exhaust pipe from the manifold, then remove and discard the gasket.
Install crankshaft sprocket retainer tool SA9104E or equivalent, with the flat side toward the sprocket. Properly remove the engine front/timing chain cover; refer to the Timing Chain Cover procedure in this section.
WARNING
Be sure to properly install the crankshaft sprocket retainer tool. Failure to hold the crankshaft timing sprocket in place will cause timing chain damage.
Rotate the crankshaft clockwise to the position 90 degrees from Top Dead Center (TDC) so the timing mark and keyway align with the main bearing cap split line. This will make sure pistons will not contact the valves upon assembly.
Remove the timing chain, tensioner, guides, camshaft sprocket(s) and chain. Use a 7/8 in. (21mm) wrench to hold the camshaft when removing the sprocket bolts.
For the SOHC TBI engine, remove the throttle body assembly and cover the intake manifold opening. Be sure to remove and discard the old throttle body gasket.
Use a 6 point socket to remove the 10 cylinder head bolts in several passes of the proper sequence. Failure to follow the proper sequence or removal of the head when hot could result in head warpage or cracking. Also, the use of a 12 point socket on the cylinder head bolts may round the bolt heads.
Lift the cylinder head from the dowels, if necessary use a small prybar for leverage between the cylinder head and block bosses. Be careful not to damage the sealing surfaces if prying is necessary to remove the head from the block.
If necessary, remove the intake manifold or the exhaust manifold by loosening the mounting nuts in the proper sequence. If any cylinder head studs back out, the threads should be cleaned, the studs carefully installed and then tightened to 106 inch lbs. (12 Nm).

INSTALLATION:
Before installing the cylinder head, it should be cleaned and inspected for excessive wear or damage.
If removed, install the intake manifold and/or the exhaust manifold and new gasket(s). Tighten to specification in the proper sequence.
Clean the gasket mating surfaces. Be careful not to damage the aluminum components. Make sure the block bolt holes are clean of any residual sealer, oil or foreign matter.
Using a dial gauge at 4 points around each cylinder, check that the cylinder liners are flush or do not deviate more than 0.0005 in. (0.013mm).
Make sure the crankshaft is still 90 degrees past TDC and that the camshaft(s) are properly positioned with the dowel pin(s) at the 12 o'clock position to prevent valve damage. Install the cylinder head gasket and carefully guide the head into place over the dowels.
If the head bolts and/or the block were replaced, install the bolts and tighten in sequence to 48 ft. Lbs. (65 Nm) to insure proper clamp load, then remove the bolts.
Coat the cylinder head bolts with clean engine oil and thread the bolts by hand until finger-tight. Tighten the bolts in sequence to 22 ft. Lbs. (30 Nm).
Tighten the cylinder head bolts again, in sequence to 33 ft. Lbs. (45 Nm) for SOHC engines or to 37 ft. Lbs. (50 Nm) for DOHC engines. Install Snap-on  torque angle gauge tool 360, or equivalent, and calibrate the tool to zero. In sequence, tighten each cylinder head bolt an additional 90 degrees.
Install the timing chain, sprockets, guides and tensioner. Then install the front cover assembly. Refer to the appropriate procedures in this section.
Position a new gasket, then connect the exhaust pipe to the manifold. Install and tighten the fasteners to 23 ft. Lbs. (31 Nm).
If not already done, remove the crankshaft sprocket retainer tool. Apply a thin film of RTV sealant to the damper/pulley assembly flange and washer only. Install the crankshaft damper/pulley assembly and tighten the bolt to 158 ft. Lbs. (214 Nm) while holding the pulley with a strap wrench or block of wood.
For DOHC vehicles, install the intake manifold support brace bolts next to the alternator, then tighten the block bolt to 33 ft. Lbs. (45 Nm) and tighten the manifold bolt to 22 ft. Lbs. (30 Nm).
Apply a small drop of RTV across the cylinder head and front cover T-joints. Inspect the old camshaft cover gasket and replace if damaged. Install the gasket and the camshaft cover. Tighten the fasteners uniformly to 22 ft. Lbs. (30 Nm) for SOHC vehicles or in proper sequence to 89 inch lbs. (10 Nm) for DOHC vehicles.
Install the drive belt tensioner and tighten the bolt to 22 ft. Lbs. (30 Nm). For 1992-98 vehicles, install the idler pulley and tighten the fasteners to 20 ft. Lbs. (27 Nm).
If not done during removal, drain the engine oil and change the filter, then install the drain plug and tighten to 26 ft. Lbs. (35 Nm).
If removed, verify the gaps on all spark plugs and install. Tighten to 20 ft. Lbs. (27 Nm).
For SOHC TBI engines, install a new gasket and the throttle body assembly. Tighten the assembly retainers to 24 ft. Lbs. (33 Nm).
Install the power steering pump assembly to the bracket, then tighten the bolts to 22 ft. Lbs. (30 Nm).
If equipped, install the air conditioning compressor and bolts. Tighten the rear bracket bolts to 19 ft. Lbs. (25 Nm), then tighten the front bracket bolts to 35 ft. Lbs. (47 Nm).
Install the accessory drive belt making sure the belt is properly aligned on the pulley.
For 1992-98 vehicles with a torque axis mounting, install the 2 mount to midrail bracket nuts and tighten to 37 ft. Lbs. (50 Nm). Install the 3 upper mount to engine front cover nuts and tighten them uniformly to 37 ft. Lbs. (50 Nm). Remove the support block of wood after the assembly is installed.
Install the splash shield, then install the tire and wheel assembly. Tighten the lug nuts, in a crisscross pattern, to 103 ft. Lbs. (140 Nm).
Connect the following applicable vacuum hoses disconnected during removal.
Canister purge valve.
EGR valve.
MAP sensor, for the SOHC TBI engine only.
Brake booster vacuum hose at the intake manifold or the brake booster.
TBI unit assembly on 1991-94 SOHC Engines or the throttle body for all MFI engines.
Fuel regulator, for 1991-97 DOHC or 1995-97 SOHC engines.
Position the wiring harness and install the following applicable wire connectors removed during disassembly:
Coolant temperature and PCM connectors. These connectors are located on the rear side of the cylinder head for DOHC engines.
The single injector connector (TBI Engine) or the 4 injector connectors (MFI Engine).
IAC valve.
MAP sensor.
TPS.
EGR solenoid.
Spark plug wires from the plugs.
Oxygen sensor.
Air conditioning compressor.
Install the throttle cable bracket and tighten the fastener to 19 ft. Lbs. (25 Nm). Connect the cable, then verify that it is properly routed and not binding.
Connect the upper radiator hose at the cylinder head outlet, the de-aeration hose at the intake manifold, or the heater hose to the intake manifold or front of dash.
Apply a few drops of clean engine oil to the male fuel line fittings. Connect any fuel line fittings and install the feed/return lines.
On TBI engines, tighten the throttle body fittings to 19 ft. Lbs. (25 Nm). On MFI engines, tighten the fuel rail and pressure regulator fittings to 133 inch lbs. (15 Nm), as applicable. Install and tighten the fuel bracket retaining bolt.
Install the air cleaner and intake duct assembly.
Add engine oil and properly fill the engine cooling system.
Thoroughly inspect the engine compartment area, especially the cylinder head, to be sure that all wires, hoses and lines have been connected. Also inspect to make sure that all components and fasteners have been properly installed.
Connect the negative battery cable.
Prime the fuel system by cycling the ignition a few times without cranking the engine, then start the engine and check for leaks.
Operate the engine at idle for 3-5 minutes and listen or unusual noises. If the lifters are noisy or the cylinders are misfiring, warm the engine to normal operating temperature running at less than 2000 rpm. Once the engine is warm and the thermostat has opened, cycle the engine between idle and 3000 rpm for 10 minutes or drive the vehicle at least 5 miles to purge air from the lifters. If air cannot be purged, the faulty lifters must be replaced.
Verify proper coolant level. Add coolant, if necessary, after the engine has cooled.

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