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Engine Block Assemble

WARNING: This page is about a different car, the 2004 Saturn Ion 3, 2004 Saturn Ion 2, and 2004 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the drain plug in the water pump.
  2. Apply sealant P/N 21485278, to the plug before installation.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the coolant jacket plugs.

    Tighten:  Tighten the coolant jacket plug to 35 N.m (26 lb ft).

  4. Install the rear oil passage plugs.
  5. Apply sealant P/N 21485278, to the plugs before installation.

    Tighten:  Tighten the oil passage plug to 60 N.m (44 lb ft).

  6. Install the other oil passage plugs.
    7. Fig 1: View Of Oil Passage Plug, Oil Flow Check Valve & Water Jacket Drain Plug
    GM412447Courtesy of GENERAL MOTORS CORP.
  7. Apply sealant P/N 21485278, to the plug before installation.

    Tighten:  Tighten the oil passage plugs to 35 N.m (26 lb ft).

  8. Lubricate the crankshaft position sensor O-ring with engine oil.
  9. Install the crankshaft position sensor and bolt.

    Tighten:  Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).

    10. Fig 2: View Of Crankshaft Position Sensor
    GM630345Courtesy of GENERAL MOTORS CORP.
  10. Install the oil pressure switch.

    Tighten:  Tighten the oil pressure switch to 10 N.m (89 lb in).

    11. Fig 3: View Of Engine Oil Pressure Sensor
    GM630350Courtesy of GENERAL MOTORS CORP.
  11. Install the knock sensor and bolt.

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

    12. Fig 4: View of Knock Sensor
    GM630342Courtesy of GENERAL MOTORS CORP.
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