Front Of Engine Oil Leaks On
                                       1991-92 GM 1.9L Saturn Engines

AERA machine shops have reported engine oil leaks near the front crankshaft oil seal on 1991-92 GM 1.9L Saturn engines.  This leak is between the seal and the pulley or damper.  Both SOHC and DOHC engines have been affected from what appears to be excessive porosity of the pulley or damper.

If the leak is determined to be in this area on 1991-92 engines, pulley/damper and seal  replacement may be necessary.  A replacement pulley for the SOHC engine is available under  Part #21000756.  The DOHC engine requires a different pulley with the Part #21006009.  Both engines use the same oil seal Part #21000707.  Depending on the extent of the porosity, it may be possible to install a thin-wall sleeve on the pulley.

Dampers and pulleys built after VIN Code # NZ143903 in 1992 have been machined to provide a better sealing surface. 

                                                                          The AERA Technical Committee

                               Engine Oil in the Cooling System On
                                   1991-97 GM 1.9L VIN 8 & 9 Engines

AERA members have reported engine oil in the cooling system on 1991-97 GM 1.9L VIN 8 & 9 engines. Only Saturn vehicles equipped with this SOHC engine may encounter this condition. Symptoms of this condition may include engine overheating. The owner may also comment on continuously adding engine oil to the crankcase.

The source of this condition may be located in the rear of the cylinder head at the number four and five camshaft journal bores and areas. Cracks located in 
this area (See Illustrations Below) of the head may allow engine oil to mix with engine coolant. These cracks may have been caused by irregularities during 
manufacturing of the cylinder head. Pressure testing of the cylinder head with the camshaft installed, may not always reveal a leak. Removal of the camshaft
is necessary to successfully pressure test this cylinder head.

AERA members have successfully repaired some of the cracks in the cylinder heads. If the cracking of the cylinder head is beyond repair, Saturn recommends 
replacing the cylinder head. Replacement of the head has been covered under the normal Saturn warranty conditions.
                 
                   Year Model               Head Gasket                       Head Part Number
                                                       Part Number
                 
                    1991-94                      21008324                                   21008232
                       1995                         21007332                                   21007138
                     1996-97                      21007332                                   21006837
  
                                                                              The AERA Technical Committee

       Camshaft Support Bushing Installation Procedures On
                Cummins Small Vee Series Engines


Cummins Engine Company reports that the camshaft bushing
installation in the small vee engines is a very critical
operation, and it is essential that the correct procedures are
observed.

PREPARE THE CYLINDER BLOCK BY THOROUGHLY CLEANING AND INSPECTING:

1.  Check the camshaft bores for cracks, butts, scratches and
wear.

2.  Remove the four cylinder head plugs and two main oil rifle
plugs and clean these drillings and the main bearing to camshaft
bore drillings with a wire or nylon brush.  It is preferred that
this be done while the cylinder block is submerged in a tank of
hot cleaning solution.

3.  Remove the burrs from the lead-ion edge of the camshaft bore
with crocus cloth or similar material, giving extra attention to
the intersection of the tappet bore and the camshaft bore.

4.  Thoroughly flush the block with cleaning solution after
cleaning and removing the burrs.

5.  Check the bushing bores for the correct size with an inside
micrometer or a dial bore gauge.

6.  On older cylinder blocks that were equipped with thin wall
camshaft bushings, the camshaft bushing bores should be machined
to 2.1865 to 2.1875 (55.537 to 55.562 mm) diameter to
accommodate the current camshaft bushing.

INSTALLING THE CAMSHAFT BUSHINGS IN THE CYLINDER BLOCK:

1.  Use Service Tool, Part No. 3376037,* (small cam) and Part No.
3376143,* (big cam), to install the camshaft bushings in the
cylinder block.

2.  When installing the camshaft bushings, make sure the oil
holes in the bushings are aligned with the oil holes in the
block.  The oil drain hole at the front of number one camshaft
must be open.  If the oil drain hole is blocked, full engine oil
pressure is applied to the end of the camshaft, and can cause
severe wear. 

3.  Install the camshaft bushings dry.

4.  Install the interior camshaft bushings on the installation
tool, the notched end first.


INSTALL THE NUMBER THREE CAMSHAFT BUSHING FIRST FROM THE FRONT
END OF THE CYLINDER BLOCK, USING THE INSTALLATION TOOL:

1.  Insert the tool (smaller diameter first) into the cylinder
block through the No. 1 camshaft bore.  Continue pushing the tool
in until the small diameter of the tool is through the No. 2
bore.  Install an intermediate camshaft bushing on the tool, with
notched end away from the centerbore.  Continue pushing the tool
in until the small diameter of the tool goes through the
centerbore and the camshaft bushing is against the shoulder of
the large diameter of the tool and is ready to start into the
bore.  Using the slide hammer adapter from Kit No. ST-1228,* or a
soft hammer, drive the camshaft bushing into the block bore. 
Withdraw the tool until the small diameter of the tool clears the
No. 2 bore.  Install another intermediate camshaft bushing on the
tool and push it back in until the camshaft bushing is ready to
start in the bore.  Then, drive the camshaft bushing into the
block bore.  Withdraw the tool from the cylinder block, install
the bushing for the No.l 1 bore on the tool.  Install the tool
through the No. 1 bore and push it in until the camshaft bushing
contacts the No. 1 bore, drive camshaft bushing into the bore. 
Withdraw the tool from the cylinder block, install it through No.
5 bore small diameter of the tool first.  Install a camshaft
bushing on the tool, notched end away from the No. 4 bore (V8
engines).  Continue pushing the tool in until the camshaft
bushing contacts No. 4 bore.  Then, drive the camshaft bushing
into the bore.   Withdraw the tool from the cylinder block. 
Install the camshaft bushing for No. 5 bore on the tool and drive
it into the bore.

2.  Check the camshaft bushing oil supply drillings from the
bottom of the cylinder block for any metal shavings after the
installation.  Also, check the alignment of the oil holes of the
camshaft bushing and the cylinder block bore.  (Use a 7/64 [2.78
mm] wire to ensure maximum hole opening).

CHECK THE INSTALLED CAMSHAFT BUSHINGS FOR PROPER ALIGNMENT AND
FIT:

1.  The alignment of the camshaft bore should be checked after
the camshaft bushings are installed with an alignment checking
bar or by installing the camshaft.  With the engine upside down
the camshaft should turn freely without binding.  When the
camshaft is used to check alignment, install it using the pilot
tool, Part No. 3376324,* (small cam) and Part No. 3376325,* (big
cam) and the assistance of another person or with the block in
the vertical position.  Camshaft bushings can be damaged by the
camshaft at installation or removal.  Therefore, extreme care
should be used when installing or removing the camshaft.

2.  If binding is encountered, Do Not Force or Drive!  Remove
camshaft and check the bushings for distortion or burrs.

INSTALLATION OF THE CAMSHAFT DURING FINAL ENGINE ASSEMBLY:

1.  Install the camshaft with the block upside down using the
pilot tool and the assistance of another person, or with the
block in the vertical position.

2.  Prior to assembly, coat the camshaft bushing and the camshaft
bearing journals with lubriplate.

3.  Slowly rotate the camshaft as it is inserted into the
cylinder block.  There should be no binding as the camshaft is
inserted into the bushings.  If binding is encountered, remove
camshaft and check the bushing for distortion or burrs.


RUN IN/DYNAMOMETER

1.  Prelube the engine to obtain at least a minimum of 15 psi
(103.41 kPa) on the engine oil pressure gauge.

2.  Crank the engine at least 15 seconds while maintaining
external oil pressure at a minimum of 15 psi (103.41 kPa).  

3.  Start the engine and idle at approximately 800 to 1000 rpm -
no load for 5 to 10 minutes.

4.  Apply light load 25 to 50 hp until normal engine temperature
is reached.

5.  Finish engine test per normal procedure.

* Tools may be ordered from Cummins Dealers or Distributors.


                                     The AERA Technical Committee


February 1981 - SPB 74 

##END##

                                                  Oil Consumption On
                                       1990-92 GM 1.9L Saturn Engines 

AERA members have reported instances of oil consumption on 1990-92 GM 1.9L Saturn engines.  GM considers excessive oil consumption on this engine to be more than one quart of oil (.95 liter) per 3,000 miles (4827 km).  This condition may result from oil passing by worn valve stem seals into the combustion process.

If cylinder compression values are within the normal range of 185-205 psi (1,276-1,344 kPa) and valves are not damaged, installing new seals Part #21006516 should solve this problem.  It is also possible to install new valve seals without removing the cylinder head from the block with the proper tools.

If cylinder compression values are lower than normal, performing a cylinder leakdown test may indicate further engine disassembly is required.

Another consideration for oil consumption is a problem with the positive crankcase ventilation system, which is described in AERA Technical Bulletin TB-791.

                                                                           The AERA Technical Committee