3.0 l engine

2003 ENGINE
Engine Mechanical - 3.0L (L81) - Saturn L Series
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications
Application
Specification
Metric English
A/C Compressor Bolts 20 N.m 15 lb ft
A/C Compressor Bracket Bolt 40 N.m 30 lb ft
A/C Compressor and Power Steering Pump Bracket Bolts 40 N.m 30 lb ft
Air Box Mount Bolt 6 N.m 53 lb in
Battery Terminal Bolts 17 N.m 13 lb in
Belt Tensioner Bolts 40 N.m 30 lb ft
Brake Vacuum Line 20 N.m 15 lb ft
Camshaft Bearing Cap Bolt 8 N.m 71 lb in
Camshaft Cover Bolts 8 N.m 71 lb ft
Camshaft Sprocket Bolt
 First Pass 50 N.m 37 lb ft
 Second Pass 60 degrees
 Final Pass 15 degrees
Connecting Rod Cap Bolts
Coolant Bridge Bolt 30 N.m 22 lb ft
Coolant Extension Housing Bolt 20 N.m 15 lb ft
Coolant Intake Housing Bolts 20 N.m 15 lb ft
Coolant Pipe/Engine Lift Bracket Bolt 20 N.m 15 lb ft
Crankshaft Balancer Bolt 20 N.m 15 lb ft
Crankshaft Bearing Bridge Adjusting Sleeves 8 N.m 71 lb in
Crankshaft Bearing Bridge Bolts 20 N.m 15 lb ft
Crankshaft Bearing Cap
2003 Saturn L200
2003 ENGINE Engine Mechanical - 3.0L (L81) - Saturn L Series
2003 Saturn L200
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Monday, May 09, 2011 12:20:05 PM Page 1 © 2006 Mitchell Repair Information Company, LLC.
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Crankshaft Drive Gear Bolt
Crankshaft Position Sensor Bolt 8 N.m 71 lb in
Crankshaft Reluctor Ring Screw 15 N.m 11 lb ft
Cylinder Head Bolt
 Third Pass 90 degrees
 Fourth Pass 90 degrees
EGR Manifold Bolt 8 N.m 71 lb in
EGR Pipe Bolts 25 N.m 18 lb ft
Engine Control Module Bolts 8 N.m 71 lb in
Engine Lift Bracket Bolts 8 N.m 71 lb in
Engine Mount Bracket Bolt 55 N.m 41 lb ft
Engine Mount-to-Bracket Bolt 55 N.m 41 lb ft
Engine Mount-to-Frame Bolt 55 N.m 41 lb ft
Engine Oil Cooler Cover Bolt 30 N.m 22 lb ft
Engine Oil Cooler Inlet and Outlet Nut 20 N.m 15 lb ft
Engine Ventilation Chamber Bolts 8 N.m 71 lb in
Exhaust Manifold Nut 20 N.m 15 lb ft
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts 30 N.m 25 lb ft
Flex Plate Bolt
Front Timing Belt Cover Bolt 8 N.m 71 lb in
Fuel Rail Bolts 8 N.m 71 lb in
Generator Mounting Bolts 40 N.m 30 lb ft
Idler Pulley Bolt 40 N.m 30 lb ft
Idler Pulley Fastener 40 N.m 30 lb ft
Ignition Module Bolt 8 N.m 71 lb in
Intake Manifold Bolt 20 N.m 15 lb ft
Intake Manifold Runner Bolts 8 N.m 71 lb in
Intake Manifold Runner Bracket Bolt 20 N.m 15 lb ft
Intake Manifold Spacer Plate Bolt 20 N.m 15 lb ft
2003 Saturn L200
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ENGINE MECHANICAL SPECIFICATIONS
Engine Block Specifications
Intake Plenum Bolts 8 N.m 71 lb in
Lower Engine-to-Transaxle Bell Housing Bolts 65 N.m 48 lb ft
Nose Cone Bracket-to-Oil Pan Bolts - Transaxle Nose
Bracket Bolts
40 N.m 30 lb ft
Oil Cooler Feed and Return Lines to Engine Block 30 N.m 22 lb ft
Oil Drain Plug 10 N.m 89 lb in
Oil Filter Cap 15 N.m 11 lb ft
Oil Filter Cartridge Housing-to-Engine 45 N.m 33 lb ft
Oil Level Indicator Tube Bolt 20 N.m 15 lb ft
Oil Pan Baffle Bolt 8 N.m 71 lb in
Oil Pan Bolts 15 N.m 11 lb ft
Oil Pickup Tube bolts 8 N.m 71 lb in
Oil Pump Bolts 27 N.m 20 lb ft
Oxygen Sensors - Exhaust Manifold 50 N.m 37 lb ft
Power Steering Pump Bolts 20 N.m 15 lb ft
Power Steering Pump Pulley Bolt 20 N.m 15 lb ft
Rear Timing Belt Cover Bolt 8 N.m 71 lb ft
Rear Timing Belt Cover Threaded Pin 10 N.m 89 lb in
Spark Plug 25 N.m 18 lb ft
Thermostat Housing Bolts 20 N.m 15 lb ft
Throttle Body Nut 8 N.m 71 lb in
Timing Belt Tensioner Bracket Bolt 40 N.m 30 lb ft
Timing Belt Tensioner Fastening Nut 20 N.m 15 lb ft
Torque Converter Bolts 65 N.m 48 lb ft
Transaxle Mount Through Bolt 55 N.m 41 lb ft
Transaxle-to-Oil Pan Bolts 65 N.m 48 lb ft
Upper Bell Housing Bolts 65 N.m 48 lb ft
Upper Pulley Bolt 40 N.m 30 lb ft
Ventilation Housing Bolts 8 N.m 71 lb in
Water Pump Bolt 25 N.m 18 lb ft
Water Pump Pulley Bolt 8 N.m 71 lb in
Wheel Bolts 125 N.m 92 lb ft
Application
Service Limit
Metric English
Cylinder Bore - Select Fit Designation Stamped on Block
 (8) 85.975-85.985 mm 3.3848-3.3852 in
 (99) 85.985-85.995 mm 3.3852-3.3856 in
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 (00) 85.995-86.005 mm 3.3856-3.3860 in
 (01) 86.005-86.015 mm 3.3860-3.3864 in
 (02) 86.015-86.025 mm 3.3864-3.3868 in
 (7 + 0.5) Oversize 86.465-86.475 mm 3.4041-3.4045 in
 Maximum Out-of-Round 0.065 mm 0.0003 in
 Taper 0.0065 mm 0.0003 in
Piston - Select Fit Designation Stamped on Top of Piston
 (8) 85.940-85.950 mm 3.3834-3.3838 in
 (99) 85.950-85.960 mm 3.3838-3.3842 in
 (00) 85.960-85.970 mm 3.3842-3.3846 in
 (01) 85.970-85.980 mm 3.3846-3.3850 in
 (02) 85.980-85.990 mm 3.3850-3.3854 in
 (7 + 0.5) Oversize 86.430-86.440 mm 3.4027-3.4031 in
 Piston Bore Clearance 0.025-0.045 mm 0.0010-0.0018 in
 Piston Pin Diameter 21 mm 0.8267 in
 Clearance in Piston 0.003-0.008 mm 0.0001-0.0003 in
Piston Ring - Compression
 Thickness 1.5 mm 0.0590 in
 Ring Groove Clearance 0.02-0.04 mm 0.0008-0.0015 in
 Ring Gap 0.30-0.50 mm 0.0118-0.0196 in
Piston Ring - Oil
 Thickness 3.0 mm 0.1181 in
 Ring Groove Clearance 0.01-0.03 mm 0.0004-0.0012 in
 Ring Gap 0.40-1.40 mm 0.0157-0.0551 in
Piston Pin
 Diameter 21 mm 0.8267 in
 Clearance in Piston 0.001-0.015 mm 0.0001-0.0003 in
Crankshaft - Main Journal
 Standard Size - Green 67.980-67.988 mm 2.6763-2.6766 in
 Standard Size - Brown 67.988-67.996 mm 2.6766-2.6770 in
 Undersize - 0.25 - Green/Blue 67.730-67.738 mm 2.6656-2.6668 in
 Undersize - 0.25 - Brown/Blue 67.738-67.746 mm 2.668-2.6671 in
 Undersize - 0.50 - Green/White 67.480-67.488 mm 2.666-2.6570 in
 Undersize - 0.50 - Brown/Blue 67.488-67.496 mm 2.6570-2.6573 in
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Cylinder Head Specifications
 Main Journal Maximum Out-of-Round 0.03 mm 0.0012 in
 Crankshaft Bearing Clearance 0.014-0.043 mm 0.0006-0.0017 in
 Crankshaft End Play 0.010-0.76 mm 0.0004-0.0300 in
 Connecting Rod Journal Diameter 48.971-48.990 mm 1.927-1.928 in
 Undersize - 0.25 48.721-48.740 mm 1.918-1.919 in
 Undersize - 0.50 48.471-48.490 mm 1.908-1.909 in
Connecting Rod
 Side Clearance 0.07-0.28 mm 0.0027-0.0110 in
 Bearing Clearance 0.013-0.061 mm 0.0005-0.0024 in
 Big End Diameter 52.000-52.012 mm 2.0472-2.0477 mm
Measurement
Standard Service Limit
Metric English Metric English
Compression (Hot)
250 RPM (Open
Throttle) 1310 kPa 190 psi min 1,241 kPa 180 psi min
Cylinder Leakage (Hot)
689 kPa (100 psi)
Input 69 kPa 10% max 10 psi max 138 kPa 15% max 20 psi max
Cylinder Head
Total Height 134.0 mm 5.276 in 133.9-134.1 mm 5.272-5.280 in
Maximum Distortion
(Length)
- -
0.05/100 mm 0.0020/3.937 in
Valve
Lifter - - - -
Face Angle - - - 45 degrees
Seat Angle - - - 45 degrees
Seat Width - - - -
Intake 1.0-1.4 mm 0.0394-0.0551 in - -
Exhaust 1.4-1.8 mm 0.0551-0.0709 in - -
Valve Length - Production
Intake 102.1 mm 4.016 in - -
Exhaust 92.25 mm 3.632 in - -
Valve Length - Service
Intake 101.7 mm 4.0039 in - -
Exhaust 91.8 mm 3.6141 in - -
Valve Stem Diameter
Standard (K) Intake 5.955-5.970 mm 0.2344-0.2350 in - -
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SEALERS, ADHESIVES, AND LUBRICANTS
Sealers, Adhesives, and Lubricants
Standard (K)
Exhaust
5.945-5.960 mm 0.2341-0.2346 in - -
Oversize (K 1-0.075)
Intake 6.030 mm 0.2374 in
- -
Oversize (K 1-0.075)
Exhaust 6.020 mm 0.2370 in
- -
Valve Guide Diameter
Standard (K) 6.000-6.012 mm 0.2362-0.2367 in - -
Oversize (K 1-0.075) 6.075-6.090 mm 0.2392-0.2398 in - -
Valve Guide
Installed Height
13.7-14.0 mm 0.5394-0.5512 in - -
Stem Clearance
Intake 0.030-0.057 mm 0.0012-0.0022 in - -
Exhaust 0.040-0.067 mm 0.0016-0.0026 in - -
Valve Height
Intake 39.2 mm 1.543 in - -
Exhaust 39.2 mm 1.543 in - -
Intake and Exhaust
Compressed at 252 N
(56.6 lbs) 34 mm 1.338 in
- -
Camshaft
Exhaust Cam Lobe
Lift Rise 8.66-8.74 mm 0.3409-0.344 in 8.61 mm 0.339 in min
Lifter Body
Diameter
32.959-32.975 mm 1.2976-1.282 in 32.947 mm 1.297 in min
Lifter Body
Clearance
0.025-0.066 mm 0.0010-0.0026 in 0.083 mm 0.003 in max
Journal Diameter 27.939-27.960 mm 1.099-1.101 in - -
Bearing Clearance 0.040-0.082 mm 0.0015-0.0020 in - -
End Play 0.04-0.144 mm 0.0016-0.0057 in - -
Spark Plug
Type
Bosch FLR-LTE, GM
P/N 90541059
-
Gap 0.9-1.1 mm 0.035-0.043 in - -
Torque - - 25 N.m 19 lb ft
Oil Pressure - Minimum
Engine Idle - at
Normal Operating
Temperature
- -
110 kPa 16 psi
2003 Saturn L200
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COMPONENT LOCATOR
DISASSEMBLED VIEWS
Application Type of Material
GM Part Number
United States Canada
Camshaft Bearing
Engine Assembly
Lubricant
1052367 992869
Camshaft Cover Sealant 12346286 10953472
Camshaft Front Bearing Cap Sealant 1052942 10953466
Camshaft Lobes
Engine Assembly
Lubricant
1052367 992869
Connecting Rod Bearings
Engine Assembly
Lubricant
1052367 992869
Coolant Jacket Plugs Sealant 12346004 10953480
Crankcase Vent Housing Sealant 1052942 10953466
Crankshaft Bearing Bridge Adjusting Sleeves Thread Adhesive 12345493 10953488
Crankshaft Main Bearings
Engine Assembly
Lubricant
1052367 992869
Crankshaft Fourth Main Bearing Cap Sealant 12346286 10953472
Flywheel Bolts Thread Adhesive 12345493 10953488
Intake Manifold Flange Bolts Thread Adhesive 12345382 10953489
Oil Cooler Cover Sealant 12378521 88901148
Oil Cooler Cover Bolts Thread Adhesive 12345382 10953489
Oil Level Indicator Tube Bolt Thread Adhesive 12345493 10953488
Oil Pan Sealant 1052942 10953466
Oil Pan Bolts Thread Adhesive 21485278 10953480
Oil Pump Bolts Thread Adhesive 21485278 10953480
Oil Pump Pickup Brace Bolts Thread Adhesive 12345382 10953489
Thermostat Housing Bolts Sealant 12346004 10953480
Timing Belt Rear Cover Bolt Thread Adhesive 12345382 10953489
Water Pump Pulley Bolts Thread Adhesive 12345382 10953489
Water Pump Seal Silicone 12345579 1974984
Valve Lifter
Engine Assembly
Lubricant
1052367 992869
2003 Saturn L200
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Fig. 1: Front of Engine Disassembled View
Courtesy of GENERAL MOTORS CORP.
Callouts For Fig. 1
Callout Component Name
1 Timing Belt Front Cover Bolt
2 Timing Belt Front Cover Seal
3 Timing Belt
4 Timing Belt Tensioner Bracket Bolt
5 Timing Belt Tensioner Bracket, Includes 1-2 Idler Pulley and Tensioner
6 Water Pump
7 Timing Belt Rear Cover
8 Camshaft Sprocket Bolt
9 Camshaft Sprocket Washer
10 Camshaft Sprocket
11 3-4 Timing Belt Idler
12 3-4 Timing Belt Idler Bolt
13 Oil Pump Collar
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14 Timing Belt Rear Cover Bolt
15 Water Pump Bolt
16 Crankshaft Pulley
17 Crankshaft Pulley Bolt
18 Crankshaft Balancer
19 Crankshaft Balancer Bolt
20 Timing Belt Front Cover
21 Water Pump Pulley
22 Water Pump Pulley Bolts
2003 Saturn L200
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2003 Saturn L200
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Fig. 2: Crankshaft/Pistons Disassembled View
Callouts For Fig. 2
1 Piston Pin Retaining Clip
2 Piston Pin
3 Upper Compression Ring
4 Lower Compression Ring
5 Oil Control Rings
6 Connecting Rod
7 Connecting Rod Bearing
8 Connecting Rod Cap
9 Connecting Rod Bolt
10 Crankshaft Sensor
11 Flywheel Bolt
12 Flywheel
13 Crankshaft Sensor Reluctor Ring Bolt
14 Crankshaft Sensor Reluctor Ring
15 Crankshaft Lower Main Bearings
16 Crankshaft Main Bearing Cap Bolt
17 Crankshaft Main Bearing Caps
18 Crankshaft Bearing Bridge
19 Crankshaft Bearing Bridge Bolt
20 Crankshaft Bearing Bridge Adjusting Sleeve
21 Crankshaft
22 Crankshaft Upper Main Bearings
23 Left Knock Sensor
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Fig. 3: Manifold and Related Disassembled View
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Callouts For Fig. 3
1 Fuel Injection Rail
2 Fuel Injection Fuel Feed and Return Bolt
3 Fuel Injector Fuel Feed and Return
4 Intake Plenum Bolt Cap
5 PCV Vent Tube Adapter Bolt
6 PCV Vent Tube Adapter
7 Intake Manifold Tuning Valve
8 Intake Manifold Tuning Valve Actuator
9 Intake Manifold Tuning Valve Bolt
10 Intake Manifold Tuning Valve Solenoid Valve Hose
11 Intake Manifold Tuning Valve O-ring
12 Intake Manifold Plenum Bolt
13 PCV Vent Tube Adapter O-ring
14 Idle Air Valve
15 Intake Plenum
16 Intake Manifold
17 Intake Manifold Gasket
18 Intake Manifold Flange
19 Intake Manifold Flange Gasket
20 Intake Manifold Flange Bolt
21 Intake Manifold Bolt
22 Intake Plenum O-ring
23 Throttle Body Bolt
24 Throttle Body
25 Throttle Body O-ring
26 Ignition Coil Cassette
27 Left Exhaust Manifold
2003 Saturn L200
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Fig. 4: Cylinder Head and Components Disassembled View
Callouts For Fig. 4
1 Camshaft Bearing Cap
2 Camshaft Bearing Cap Bolt
3 Exhaust Camshaft
4 Intake Camshaft
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5 Camshaft Cover Bolt
6 Camshaft Cover
7 Oil Fill Tube
8 Oil Fill Cap O-ring
9 Oil Fill Cap
10 Camshaft Cover Gasket
11 Camshaft Cover O-ring
12 Left Cylinder Head
13 Left Cylinder Head Gasket
14 Valve
15 Valve Spring Seat
16 Valve Seal
17 Valve Spring
18 Valve Spring Cap
19 Valve Spring Retaining Keys
20 Valve Lifter
21 Right Cylinder Head Gasket
22 Camshaft Seal
23 Right Cylinder Head
24 Cylinder Head Bolt
2003 Saturn L200
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Fig. 5: Oil Pan and Delivery Components Disassembled View
Callouts For Fig. 5
1 Oil Cooler Inlet/Outlet Nuts
2 Oil Cooler Pipe Seals
3 Oil Cooler Line Banjo Fittings
4 Oil Cooler Inlet Pipe
5 Oil Cooler Outlet Pipe
6 Oil Filter Adapter
7 Oil Filter Bypass Valve
8 Oil Filter Bypass Check Ball
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ENGINE IDENTIFICATION
9 Oil Filter Bypass Spring
10 Oil Pan Baffle
11 Oil Pan
12 Oil Pump Gasket
13 Oil Pump Pipe Plug
14 Oil Intake Pipe O-ring
15 Oil Intake Pipe
16 Oil Intake Pipe Bolt
17 Oil Pump Inlet Screen
18 Oil Intake Pipe Bolt
19 Oil Pump Collar
20 Oil Pump
21 Oil Pressure Relief Valve
22 Oil Pressure Relief Valve Spring
23 Oil Pressure Relief Valve Seal
24 Oil Pressure Relief Valve Plug
25 Oil Pressure Regulator Valve Spring
26 Oil Pressure Regulator Valve
27 Oil Pressure Regulator Valve Seal
28 Oil Pressure Regulator Valve Plug
29 Oil Cooler
30 Oil Cooler Inlet/Outlet Seals
31 Oil Cooler Cover
32 Oil Cooler Cover Bolt
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Fig. 6: Locating Engine Identification Markings
The Vehicle Identification Number (VIN) Derivative (2) is located on the lower right side of the engine block
and is a nine digit number stamped or laser etched onto the engine at the vehicle assembly plant. If reading the
identification number from the left, the following information can be obtained:
 The first digit identifies the vehicle division.
 The second digit identifies the model year.
 The third digit identifies the assembly plant.
 The fourth through ninth digits are the last six digits of the Vehicle Identification Number (VIN).
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Engine displacement (1) is cast into the engine block under the starter motor.
DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL
Begin the system diagnosis by reviewing the Disassembled Views, Engine Component Description,
Lubrication Description and the Drive Belt System Description. Reviewing the description and operation
information will help you determine the correct symptom diagnostic procedure when a malfunction exists.
Reviewing the description and operation information will also help you determine if the condition described by
the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct
procedure for diagnosing the system and where the procedure is located.
SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
1. Perform a Diagnostic Starting Point - Engine Mechanical before using the symptom tables, if
applicable.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to
Disassembled Views, Engine Component Description, Lubrication Description and the Drive Belt
System Description.
All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for
repairing all systems. The diagnostic flow may always be used in order to resolve a system problem. The
diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to Strategy
Based Diagnosis in General Information.
Visual/Physical Inspection
 Inspect for aftermarket devices which could affect the operation of the Engine. Refer to Checking
Aftermarket Accessories in Wiring Systems.
 Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
 Check for the correct oil level, proper oil viscosity, and correct filter application.
 Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM,
ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
 Compare the engine sounds - if applicable to a known good engine and make sure you are not trying to
correct a normal condition.
Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system is operating
properly.
Symptom List
2003 Saturn L200
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Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
 Base Engine Misfire without Internal Engine Noises
 Base Engine Misfire with Abnormal Internal Lower Engine Noises
 Base Engine Misfire with Abnormal Valve Train Noise
 Base Engine Misfire with Coolant Consumption
 Base Engine Misfire with Excessive Oil Consumption
 Engine Noise on Start-Up, but Only Lasting a Few Seconds
 Upper Engine Noise, Regardless of Engine Speed
 Lower Engine Noise, Regardless of Engine Speed
 Engine Noise Under Load
 Engine Will Not Crank - Crankshaft Will Not Rotate
 Engine Compression Test
 Oil Consumption Diagnosis
 Oil Pressure Diagnosis and Testing
 Oil Leak Diagnosis
BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES
Base Engine Misfire without Internal Engine Noises
Cause Correction
Abnormalities - severe cracking, bumps, or missing
areas in the accessory drive belt
Abnormalities in the accessory drive system and/or
components may cause engine RPM variations and
lead to a misfire DTC. A misfire code may be
present without an actual misfire condition.
Replace the drive belt. Refer to Drive Belt
Replacement.
Worn, damaged, or mis-aligned accessory drive
components or excessive pulley runout and may
lead to a misfire DTC.
A misfire code may be present without an actual
misfire condition.
Inspect the components, repair or replace as
required.
Improperly installed or damaged vacuum hoses Repair or replace as required.
Improperly installed or damaged MAP sensor
and/or seal
The sealing grommet of the MAP sensor should not
be torn or damaged
Repair or replace the MAP sensor as required.
Improperly installed or damaged EVAP purge
solenoid and/or O-ring seal
Repair or replace the EVAP purge solenoid as
required.
Restricted exhaust system
A severe restriction in the exhaust flow can cause
significant loss of engine performance and may set a
DTC. Possible causes of restrictions include
Repair or replace as required.
2003 Saturn L200
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collapsed or dented pipes or plugged mufflers
and/or catalytic converters.
Excessively worn or mis-aligned timing belt Replace the timing belt and sprockets as required.
Worn camshaft lobes Replace the camshaft or camshafts and SHLAs,
valve lifters.
Excessive oil pressure
A lubrication system with excessive oil pressure
may lead to excessive valve lifter pump-up and loss
of compression.
 Perform an oil pressure test. Refer to Oil
Pressure Diagnosis and Testing.
 Repair or replace the oil pump as required.
Stuck valves
Carbon buildup on the valve stem can cause the
valve not to close properly.
Improper sealing between the intake manifold and
cylinder heads, intake manifold and plenum duct,
plenum duct and water crossover, water crossover
and throttle body and/or pressure relief valve and
intake manifold.
Replace the intake manifold, plenum duct, gaskets,
cylinder heads, throttle body and/or pressure relief
valve as required.
Faulty cylinder head gaskets and/or cracking or
other damage to the cylinder heads and engine block
cooling system passages. Refer to Diagnostic
Starting Point - Engine Cooling in Engine
Cooling.
Coolant consumption may or may not cause the
engine to overheat.
 Inspect for spark plugs saturated by coolant.
Refer to SPARK PLUGS in Service &
Adjustment Specifications in Engine
Performance.
 Inspect the cylinder heads, engine block,
and/or head gaskets.
 Repair or replace as required.
Loose or improperly installed engine flywheel or
crankshaft balancer
misfire condition.
Repair or replace the flywheel and/or balancer as
required. Refer to Engine Flywheel Replacement or
Crankshaft Balancer Replacement.
Worn Piston Rings
Oil consumption may or may not cause the engine
to misfire.
 Inspect the spark plugs for oil deposits. Refer
to SPARK PLUGS in Service & Adjustment
Specifications in Engine Performance.
 Inspect the cylinders for a loss of
compression. Refer to Engine Compression
Test.
 Perform cylinder leak down and compression
testing to identify the cause.
A damaged crankshaft reluctor wheel
A damaged crankshaft reluctor wheel can result in
different symptoms depending on the severity and
location of the damage.
 Systems with SEVERE reluctor ring damage
may exhibit periodic loss of crankshaft
Replace the crankshaft as required.
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BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES
Base Engine Misfire with Abnormal Internal Lower Engine Noises
BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE
Base Engine Misfire with Abnormal Valve Train Noise
position, stop delivering a signal, and then re-
sync the crankshaft position.
 Systems with SLIGHT reluctor ring damage
may exhibit no loss of crankshaft position and
no misfire may occur. However, a P0300
DTC may be set.
Cause Correction
Abnormalities - severe cracking, bumps or missing
areas- in the accessory drive belt
Abnormalities in the accessory drive system and/or
components may cause engine RPM variations,
noises similar to a faulty lower engine and also lead
to a misfire condition. A misfire code may be
present without an actual misfire condition.
Replacement.
Worn, damaged, or mis-aligned accessory drive
components or excessive pulley runout
misfire condition.
Inspect the components, repair or replace as
required.
Loose or improperly installed engine flywheel or
crankshaft balancer
misfire condition.
Repair or replace the engine flywheel and/or
crankshaft balancer as required. Refer to Engine
Flywheel Replacement or Crankshaft Balancer
Replacement.
Worn or Broken Piston Rings
to misfire.
Test.
testing to determine the cause.
Worn Crankshaft Thrust Bearings
Severely worn thrust surfaces on the crankshaft
and/or thrust bearing may permit fore and aft
movement of the crankshaft and create a DTC
without an actual misfire condition.
Replace the crankshaft and bearings as required.
2003 Saturn L200
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BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION
Base Engine Misfire with Coolant Consumption
BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION
Base Engine Misfire with Excessive Oil Consumption
ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS
Cause Correction
Excessively worn or mis-aligned timing belt Replace the timing belt as required.
Worn camshaft lobes Replace the camshaft or camshafts and SHLAs -
valve lifters.
Sticking SHLAs - valve lifters Replace the SHLAs as required.
Stuck valves
Carbon buildup on the valve stem can cause the
valve not to close properly.
Cause Correction
Faulty cylinder head gaskets and/or cracking or
other damage to the cylinder heads and engine
block cooling system passages. Refer to Diagnostic
Starting Point - Engine Cooling in Engine
Cooling.
Coolant consumption may or may not cause the
engine to overheat.
 Inspect for spark plugs saturated by coolant.
Refer to SPARK PLUGS in Service &
Adjustment Specifications in Engine
Performance.
 Perform a cylinder leak down test.
 Inspect the cylinder heads and engine block
for damage to the coolant passages and/or a
faulty head gasket.
Cause Correction
Worn valves, valve guides and/or valve stem oil
seals
Worn Piston Rings
to misfire.
Test.
testing to determine the cause.
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Engine Noise on Start-Up, but Only Lasting a Few Seconds
UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Upper Engine Noise, Regardless of Engine Speed
Cause Correction
Incorrect oil filter without anti-drainback feature Install the correct oil filter.
Incorrect oil viscosity Drain the engine oil and replace with the correct
viscosity oil.
Damaged or faulty oil filter by-pass valve  Inspect the oil filter by-pass valve for proper
operation.
High SHLA, valve lifter, leak down rate Replace the SHLA, valve lifters, as required.
Worn crankshaft thrust bearing  Inspect the thrust bearing and crankshaft.
Cause Correction
Low oil pressure  Perform an oil pressure test. Refer to Oil
Improper lubrication to the valve lifters Inspect the following components, and repair or
replace as required:
 The SHLA - valve lifter
 The oil filter bypass valve
 The oil pump and pump screen
 The cylinder head oil galleries
 The engine block oil galleries
Worn or dirty SHLAs, valve lifters Replace the SHLAs - valve lifters.
Stretched or broken timing belt and/or damaged
sprocket teeth
Replace the timing belt and sprockets.
Worn timing belt tensioner or tensioners Replace the timing belt tensioner or tensioners as
required.
Worn engine camshaft lobes  Inspect the engine camshaft lobes.
 Replace the camshaft or camshafts and
SHLAs, valve lifters, as required.
Worn valve guides or valve stems Inspect the following components, and repair as
required:
 The valves
 The valve guides
Stuck Valves Inspect the following components, and repair as
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LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
Lower Engine Noise, Regardless of Engine Speed
Carbon on the valve stem or valve seat may cause
the valve to stay open
required:
 The valves
 The valve guides
Cause Correction
Worn accessory drive components
Abnormalities such as severe cracking, bumps or
missing areas in the accessory drive belt and/or
misalignment of system components.
 Inspect the accessory drive system.
Detonation or spark knock Verify the correct operation of the ignition controls
system. Refer to DETONATION/SPARK
KNOCK in Troubleshooting - No Codes in Engine
Performance.
 Repair or replace damaged components as
required.
Loose or damaged crankshaft balancer  Inspect the crankshaft balancer.
Loose torque converter bolts  Inspect the torque converter bolts and engine
flywheel.
Loose or damaged engine flywheel Repair or replace the engine flywheel.
Oil pump screen loose, damaged or restricted  Inspect the oil pump screen.
Incorrect piston, piston pin and connecting rod
installation
Pistons must be installed with the mark or dimple
on the top of the piston facing the front of the
engine. Piston pins must be centered in the
connecting rod pin bore.
 Verify the pistons, piston pins and connecting
rods are installed correctly.
 Repair as required.
Excessive crankshaft bearing clearance Inspect the following components, and repair as
required:
 The crankshaft bearings
 The crankshaft journals
Excessive connecting rod bearing clearance Inspect the following components, and repair as
required:
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ENGINE NOISE UNDER LOAD
Engine Noise Under Load
ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE
 The connecting rod bearings
 The connecting rods
 The crankshaft
Excessive piston-to-cylinder bore clearance  Inspect the piston and cylinder bore.
Excessive piston pin-to-bore clearance  Inspect the piston, piston pin, and the
connecting rod.
Cause Correction
Detonation or spark knock Verify the correct operation of the ignition controls.
Refer to DETONATION/SPARK KNOCK in
Troubleshooting - No Codes in Engine Performance.
Loose torque converter bolts  Inspect the torque converter bolts and engine
flywheel.
Cracked engine flywheel  Inspect the engine flywheel and bolts.
Excessive connecting rod bearing clearance Inspect the following components, and repair as
required:
 The connecting rod bearings
 The connecting rods
 The crankshaft
Excessive crankshaft bearing clearance Inspect the following components, and repair as
required:
 The crankshaft bearings
 The cylinder block crankshaft bearing bore
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Engine Will Not Crank - Crankshaft Will Not Rotate
Cause Correction
Seized accessory drive system component 1. Remove accessory drive belt or drive belts.
2. Rotate crankshaft by hand at the crankshaft
balancer or engine flywheel location.
3. Repair or replace as required.
Hydraulically locked cylinder
 Coolant/Antifreeze in cylinder
 Oil in cylinder
 Fuel in cylinder
1. Remove spark plugs and check for fluid.
2. Inspect for broken head gasket or gaskets.
3. Inspect for cracked engine block or cylinder
head.
4. Inspect for a sticking fuel injector.
Seized or broken camshaft 1. Inspect camshaft or camshafts.
2. Inspect cylinder head camshaft journals for
damage.
3. Repair as required.
Seized or broken camshaft timing components 1. Inspect the following sprockets:
 Crankshaft sprocket
 Exhaust sprockets
 Intake sprockets
2. Inspect the timing belt.
3. Inspect the following tensioners:
 Timing belt idler pulley for camshaft
gears 1 and 2
 Timing belt idler pulley for camshaft
gears 3 and 4
 Timing belt tensioner
Seized or broken valve train components 1. Inspect lifters.
2. Inspect valves.
3. Inspect cams.
Seized automatic transmission torque converter 1. Remove the torque converter bolts.
Seized manual transmission 1. Disengage the clutch.
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COOLANT IN COMBUSTION CHAMBER
Coolant in Combustion Chamber
Material in cylinder
 Broken valve
 Piston material
 Foreign material
1. Inspect cylinder for damaged components
and/or foreign materials.
Seized crankshaft or connecting rod bearings 1. Inspect crankshaft and connecting rod
bearings.
Bent or broken connecting rod 1. Inspect connecting rods.
Broken crankshaft 1. Inspect crankshaft.
Cause Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may
indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty
thermostat may lead to an "overtemperature" condition which may cause engine component damage.
1. A slower than normal cranking speed may indicate coolant entering the combustion chamber. Refer
to Engine Will Not Crank - Crankshaft Will Not Rotate.
2. Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder
bore.
3. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the
coolant may indicate a faulty gasket or damaged component.
4. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine
block, with low compression, may indicate a failed cylinder head gasket. Refer to Engine
Compression Test.
Cracked intake manifold or failed gasket Replace the components as required.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning and
Inspection and Cylinder Head Replacement
(Front) or Cylinder Head Replacement (Rear).
Warped cylinder head Machine the cylinder head to the proper flatness, if
applicable and replace the cylinder head gasket.
Refer to Cylinder Head Cleaning and Inspection.
Cracked cylinder head Replace the cylinder head and gasket.
Cracked cylinder liner or engine block Replace the components as required.
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COOLANT IN ENGINE OIL
Coolant in Engine Oil
ENGINE COMPRESSION TEST
Tools Required
SA9127E Gage Bar Set
If there is a lack of power, excessive oil consumption, or poor fuel economy, etc., measure the compression
pressure.
Cylinder head or engine block porosity Replace the components as required.
Cause Correction
DEFINITION: Foamy or discolored oil or an engine oil "overfill" condition may indicate coolant
entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may
lead to an "overtemperature" condition which may cause engine component damage. Contaminated
engine oil and oil filter should be changed.
1. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not
properly lubricate the crankshaft bearings and may lead to component damage. Refer to Lower
Engine Noise, Regardless of Engine Speed.
2. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the
cooling system may indicate a faulty gasket or damaged component.
3. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine
block with low compression may indicate a failed cylinder head gasket. Refer to Engine
Compression Test.
Faulty external engine oil cooler Replace the components as required.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning and
Inspection and Cylinder Head Replacement
(Front) or Cylinder Head Replacement (Rear).
Warped cylinder head Machine the cylinder head to proper flatness, if
applicable, and replace the cylinder head gasket.
Refer to Cylinder Head Cleaning and Inspection.
Cracked cylinder head Replace the cylinder head and gasket.
Cracked cylinder liner or engine block Replace the components as required.
Cylinder head, block, or manifold porosity Replace the components as required.
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Fig. 7: Removing & Installing Ignition Control Modules
1. Start the engine and allow it to reach normal operating temperature.
2. Shut the engine OFF and disconnect the ignition module wiring harness plugs.
3. Remove the ignition modules. Refer to ELECTRONIC IGNITION MODULE in Removal and
Installation in Engine Performance.
4. Remove all 6 spark plugs.
CAUTION: Compression checks must be performed with the vehicle in park or
neutral and the parking brake applied.
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5. Insert the SA9127E into the spark plug hole.
6. Fully open the throttle.
7. While cranking the engine, measure the compression. The cylinder should puff or the compression gage
needle should bounce a minimum of 10 times.
8. Repeat the previous steps for each cylinder.
IMPORTANT: Always use a fully charged battery to obtain engine revolutions of a 250
RPM minimum. Do not crank the engine for more than 15 seconds.
IMPORTANT: All measurements must be completed in as short a time as possible.
Check low cylinders and make sure a minimum of 10 puffs are obtained
prior to reading the gage.
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Fig. 8: 3.0L RPO Code L81 V6 Engine Assembly
 Normal compression: Builds up quickly and evenly to specification in each cylinder.
 Low compression: Damaged piston, rings, valves, or head gasket.
IMPORTANT: No compression in 2 or more cylinders is an indication of damaged
timing chain sprockets, camshafts, and crankshaft key or pins.
IMPORTANT: The minimum compression in any one cylinder should not be less
than 70 percent of the highest cylinder. No cylinder should read less
than 690 kPa (100 psi).
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 High compression: Carbon on pistons/combustion chamber.
Fig. 9: Adding Engine Oil To Cylinder Through Spark Plug Hole
9. If the cylinder compression in one or more cylinders is low, pour a small amount (1 teaspoon) of engine
oil into the cylinder through the spark plug hole.
IMPORTANT: A cylinder leakage test can be performed to further determine the location
of the compression leakage if one or more cylinders are extremely low.
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Fig. 10: Placing Shop Towel Over Spark Plug Holes
10. Place a shop towel over the plug holes to capture any oil mist/spray.
11. Crank the engine over for a few seconds without the compression gage or spark plugs installed.
12. Repeat previous steps 4-7 and measure the compression.
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Fig. 11: Checking Piston Rings & Piston Ring Land Wear
13. If adding oil increases the compression readings the piston rings are leaking.
Compression is low on the first stroke (first gage puff) and tends to build up on following strokes, but
does not reach normal compression pressure. The compression Improves considerably with oil. Inspect
for worn or broken rings and piston ring land wear (pound out).
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Fig. 12: Fixed Timing Chain Guide Access Plug
14. If adding oil does not increase the compression:
 Valves or head gasket leaking: Compression is low on the first stroke. Compression does not tend
to build up on the following strokes. Compression does not improve with adding oil to the cylinder.
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Fig. 13: Checking Head Gasket If Two Adjacent Cylinders Have Lower Than Normal
Compression
 Head gasket: Two adjacent cylinders have lower than normal compression and adding oil to the
cylinder does not improve compression.
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15. Remove the compression tester and install the spark plugs.
Tighten: Tighten the spark plugs to 25 N.m (18 lb ft).
16. Install the ignition module.
Tighten: Tighten the ignition module bolt to 8 N.m (71 lb in).
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
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17. Connect the ignition module electrical connection.
CYLINDER LEAKAGE TEST
Tools Required
If there is a lack of power, excessive oil consumption, or poor fuel economy, etc., cylinder leakage can be
measured.
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1. Start the engine and allow it to reach normal operating temperature.
2. Disconnect both ignition module connectors.
3. Remove the ignition modules and remove the plugs.
4. Rotate the crankshaft so each cylinder to be checked is at TDC. Timing marks are located on the front
cover and vibration damper assembly for TDC verification. Access to the front crankshaft damper bolt
can be achieved from the top of the vehicle with an open end wrench. A 3.175 mm (1/8 in) brass rod can
be inserted through the spark plug hole to determine piston location relative to TDC.
CAUTION: Cylinder leakage checks must be performed with the vehicle in park
or neutral and the parking brake applied.
IMPORTANT: The piston must be located at exactly top dead center (TDC) or the
crankshaft will rotate when air pressure is applied.
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Fig. 16: Connecting Special Tools To Perform Cylinder Leakage Test
5. Attach an air supply to the SA9127E . The desired regulator In minimum pressure is 861 kPa (125 psi).
The maximum is 1 034 kPa (150 psi).
6. Insert the cylinder leakage adapter in the spark plug hole with the piston at TDC.
NOTE: Air supply for the tester should be clean and free from oil, moisture, and/or
foreign particles that might be injected into the regulator or orifice
chamber. Foreign debris can cause improper operation and erroneous
readings.
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7. Close the gate valve and adjust the regulator pressure to 689 kPa (100 psi).
8. Open the gate valve. Observe the crankshaft during this operation.
Fig. 17: Listening For Escaping Air At Throttle Body Air Inlet, Oil Fill Cap & Exhaust Outlet
1. Allow 60 seconds for the air pressure in the cylinder to stabilize. Observe the cylinder pressure
gage and record the pressure.
IMPORTANT: If the crankshaft rotates, the piston was not at TDC. The crankshaft will
have to be relocated at TDC.
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2. Listen for escaping air at the throttle body air inlet, oil fill cap, and exhaust outlet.
3. Remove the coolant bottle pressure cap and look for bubbles.
9. Repeat the previous steps on other cylinders. Record the readings.
 Normal Cylinder Leakage: 10 percent - 69 kPa (10 psi)
IMPORTANT: Make sure all cylinder leakage adapter fittings are tight and the
piston is at TDC or incorrect readings will be obtained. Check the
lower cylinders.
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 Maximum Leakage: 20 percent - 138 kPa (20 psi)
 Difference Between Cylinders: 5 percent - 34 kPa (5 psi)
10. Remove the cylinder leakage tester and install the spark plugs.
Tighten: Tighten the spark plugs to 25 N.m (18 lb ft).
11. Install the ignition modules.
Tighten: Tighten the ignition module bolt to 8 N.m (71 lb in).
12. Connect the ignition module harness plugs.
OIL CONSUMPTION DIAGNOSIS
Excessive oil consumption (not due to leaks) is the use of 0.95L (1 qt) or more of engine oil within 3200
kilometers (2,000 miles). The causes of excessive oil consumption include the following conditions:
 External oil leaks
Tighten bolts and/or replace gaskets and oil seals as necessary.
 Incorrect oil level or improper reading of oil level indicator
With the vehicle on a level surface, allow adequate drain down time and check for the correct oil level.
 Improper oil viscosity
Use recommended SAE viscosity for the prevailing temperatures.
 Continuous high speed driving and/or severe usage
 Crankcase ventilation system restrictions or malfunctioning components
 Valve guides and/or valve stem oil seals worn, or the seal omitted
Ream guides and install oversize service valves and/or new valve stem oil seals.
 Piston rings broken, improperly installed, worn, or not seated properly
Allow adequate time for rings to seat. Replace broken or worn rings as necessary.
 Piston improperly installed or misfitted
OIL PRESSURE DIAGNOSIS AND TESTING
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 With the vehicle on a level surface, allow adequate drain down time (2-3 minutes) and measure for a low
oil level.
 Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil
level indicator.
 Run the engine and verify low or no oil pressure on the vehicle gage or light.
 Listen for a noisy valve train or a knocking noise.
 Inspect for the following:
 Oil diluted by moisture or unburned fuel mixtures
 Improper oil viscosity for the expected temperature
 Incorrect or malfunctioning oil pressure sender
 Incorrect or malfunctioning oil pressure gage
 Plugged oil filter
 Malfunctioning oil bypass valve
 Remove the oil pressure sender or another engine block oil gallery plug.
 Install a oil pressure gage and measure the engine oil pressure.
 Compare the readings to specifications. Refer to Engine Mechanical Specifications.
 If the engine oil pressure is below specifications, inspect the engine for one or more of the following:
 Oil pump worn or dirty
Refer to Oil Pump Inspection.
 Oil pump-to-engine front cover bolts loose
Refer to Oil Pump Assemble.
 Oil pump screen loose, plugged, or damaged
 Oil pump screen O-ring seal missing or damaged
 Malfunctioning oil pump pressure regulator valve
 Excessive bearing clearance
Refer to Crankshaft and Bearings Cleaning and Inspection.
 Cracked, porous or restricted oil galleries
 Oil gallery plugs missing or incorrectly installed
 Broken lash adjusters
CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS
Tools Required
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High crankcase pressure indicates an excessive amount of air passing between the rings and cylinder walls into
the crankcase. A loss of engine lubricating oil into the air intake tube/filter housing or out the dipstick hole is
indicative of excessive crankcase pressure. High negative pressure or vacuum can be caused by a plugged air
filter element or restricted air intake.
Test method:
1. Remove the dipstick and connect a 0-15 kPa gage (0-16 in H2O) manometer or magnahelix in the
SA9127E Gage Bar Set to the dipstick tube.
2. Operate the engine until it reaches normal operating temperature and observe the crankcase pressure with
engine at 4,000 RPM.
3. The crankcase pressure should not exceed:
Crankcase Pressure (New Engine)
 Positive: 1 kPa (4 in) H2O Max.
 Negative: 3 kPa (12 in) H2O Max.
Crankcase Pressure (Used Engine)
 Positive: 2.5 kPa (10 in) H2O Max.
 Negative: 3.5 kPa (14 in) H2O Max.
4. If the crankcase pressure exceeds specifications, ensure the PCV system is functioning properly.
Positive Crank Case Ventilation (PCV) System
Always Perform a Visual Check of the PCV System:
 Properly mounted PCV valve, firmly seated in the grommet on rocker arm cover
 PCV Hose, grommet, fresh air hose, and clamps in place, no damage to PCV hose, rocker arm cover
grommet, fresh air hose. Ensure the clamps are on tight.
Crankcase Ventilation System Inspection/Diagnosis
CAUTION: The crankcase pressure check must be performed with the vehicle in park
or neutral and the parking brake applied.
IMPORTANT: It may be necessary to complete a compression and cylinder leakage
check for evaluation of piston rings and cylinder walls when there is high,
positive crankcase pressure. Low, negative crankcase pressure indicates
a possible restricted air intake system.
CONDITION POSSIBLE CAUSE CORRECTION
Rough Idle, Stalling or Slow Idle 1. Repair or replace hoses as
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Functional Check
If engine is idling rough, check for a clogged PCV valve or hose. Check the PCV valve identification number to
be sure the correct valve is installed. Replace as required.
Use the following procedure to determine if the PCV valve is functioning properly:
1. Remove PCV valve from cam cover grommet.
2. Run engine at idle.
3. Place your thumb over end of PCV valve to check for strong vacuum signal. If there is no vacuum
present, check for clogged hose, plugged valve or plugged intake manifold port. Replace any clogged
components or clean out plugged port.
4. Turn off engine and remove PCV valve from hose. Shake valve and listen for the plugger to rattle inside
the valve. If valve does not rattle, replace valve.
Other Crankcase Ventilation System Faults
If there is evidence of engine oil in the throttle body or air cleaner and all the PCV components appear and
function properly it may indicate excessive crankcase pressure.
OIL LEAK DIAGNOSIS
Tool Required
J 39400 Leak Detector
Most oil leaks are easily located by visual inspection and repaired by replacing and/or repairing the necessary
parts.
Use the following steps in order to find the leak:
1. Identify the fluid. Determine whether it is engine oil, automatic transmission fluid, or power steering
fluid.
2. From what point is the fluid leaking? After running the vehicle at normal operating temperature, park the
vehicle over a large sheet of paper. After a few minutes, you should be able to find the approximate
location of the leak by the drippings on the paper.
3. Visually check around the suspected component. Check around the gasket mating surfaces for leaks. A
mirror is useful for finding leaks in hard-to-reach areas.
4. If the leak still cannot be found, it may be necessary to clean the suspected area with a degreaser, steam or
Speed, Oil Leaks, Oil in Throttle
Body/Plenum, or Sludge in
Engine.
1. Clogged hose. necessary.
2. Clogged PCV valve. 2. Replace PCV valve.
Rough Idle, Stalling, or
High Idle Speed.
1. Leaking hose. 1. Replace hose.
2. Leaking PCV valve. 2. Replace PCV valve.
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spray solvent. Clean the area well, then dry the area. Operate the vehicle for several miles at normal
operating temperature and varying speeds. After operating the vehicle, visually check the suspected
component. If you still cannot locate the leak, try using the powder or black light-and-dye method.
Perform the following steps in order to use the black light-and-dye method:
1. Pour specified amount of dye into the leaking component system.
2. Operate the vehicle under normal operating conditions as directed by the J 39400 .
3. Direct the light toward the suspect area. The dyed fluid will appear as a yellow path leading to the source.
See the J 39400 kit directions for the color of the fluid and the dye mix.
Perform the following steps in order to perform the powder method:
1. Clean the suspected area.
2. Apply an aerosol-type powder - such as foot powder to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. You should be able to trace the leak path over the white
powder surface to the source.
Repairing the Leak
Once the origin of the leak has been pinpointed and traced back to its source, the cause of the leak must be
determined in order for it to be repaired properly. If a gasket is replaced, but the sealing surface is damaged, the
new gasket will not repair the leak. The surface must be repaired or replaced. Before attempting to repair a leak,
be sure that the gasket and sealing surfaces are correct.
Perform the following steps in order to check for gasket leaks:
1. Inspect the fluid level/pressure to see if it is too high.
2. Check the crankcase ventilation system for restrictions or malfunctioning components.
3. Inspect for improperly tightened fasteners or dirty/damaged threads.
4. Look for warped flanges or sealing surfaces.
5. Check for scratches, burrs, or other damage to the sealing surface.
6. Look for a damaged or worn gasket.
7. Check for cracking or porosity of the component.
8. Check for use of an improper sealant used - where applicable.
Perform the following steps in order to check for seal leaks:
1. Inspect the fluid level/pressure to see if it is too high.
2. Check the crankcase ventilation system for restrictions or malfunctioning components.
3. Check for a damaged O-ring seal bore - scratched, burred or nicked.
4. Look for a damaged or worn oil seal.
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5. Check for improper component installation.
6. Look for cracks in the component.
7. Inspect the shaft surface for scratches, nicks, or damage.
8. Check for a loose or worn bearing which may lead to premature oil seal wear.
DRIVE BELT CHIRPING DIAGNOSIS
Diagnostic Aids
The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray
a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the
drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution.
A loose or improper installation of a body component, a suspension component, or other items of the vehicle
may cause the chirping noise.
Test Description
The numbers below refer to the step number on the diagnostic table.
2: The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table.
3: The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief
period will verify the noise is related to the drive belt. When removing the drive belt the water pump may
not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belt removed.
4: Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive
belt grooves from the accumulation of rubber dust.
6: Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or
outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves
across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper
installation procedure for that pulley.
10: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was
installed.
12: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the
pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the
smooth surface of a pulley when the back side of the belt is used to drive the pulley.
14: Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a
temporary repair.
Drive Belt Chirping Diagnosis
Step Action Yes No
NOTE:
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DEFINITION: The following items are indications of chirping:
 A high pitched noise that is heard once per revolution of the drive belt or a pulley.
 It usually occurs on cold damp mornings.
Refer to BELT DRESSING NOTICE in Cautions and Notices.
1
Did you review the Symptoms - Engine Mechanical
operation and perform the necessary inspections? Go to Step 2
Go to Symptoms -
Engine Mechanical
2
Verify that there is a chirping noise.
Does the engine make the chirping noise? Go to Step 3
Go to Diagnostic
Aids
3
1. Remove the drive belt. Refer to Drive Belt
Replacement.
2. Operate the engine for no longer than 30 to 40
seconds.
Does the chirping noise still exist?
Go to Engine Noise
on Start-Up, but
Only Lasting a
Few Seconds ,
Upper Engine
Noise, Regardless
of Engine Speed ,
Lower Engine
Noise, Regardless
of Engine Speed ,
or Engine Noise
Under Load Go to Step 4
4
Inspect for severe pilling exceeding 1/3 of the belt
groove depth.
Does the belt grooves have pilling? Go to Step 5 Go to Step 6
5
Clean the drive belt pulleys with a suitable wire brush.
Did you complete the repair? Go to Step 15 Go to Step 6
6
Inspect for misalignment of the pulleys.
Are any of the pulleys misaligned? Go to Step 7 Go to Step 8
7
Replace or repair any misaligned pulleys.
8
Inspect for bent or cracked brackets.
Did you find any bent or cracked brackets? Go to Step 9 Go to Step 10
9
Replace any bent or cracked brackets.
10
Inspect for improper, loose or missing fasteners.
Did you find the condition? Go to Step 11 Go to Step 12
11
Tighten any loose fasteners. Refer to Fastener
Tightening Specifications.
12
Inspect for a bent pulley.
13
Replace the bent pulley.
2003 Saturn L200
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DRIVE BELT SQUEAL DIAGNOSIS
Diagnostic Aids
A loose or improper installation of a body component, a suspension component, or other items of the vehicle
may cause the squeal noise.
If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are
operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose
or wrong fluid, or a generator failing are suggested items to inspect.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2: The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table.
3: The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief
period will verify the squeal noise is the drive belt or an accessory drive component. When removing the
drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when
the engine is operating with the drive belt removed.
4: This test is to verify that an accessory drive component does not have a seized bearing. With the belt
removed, test the bearings in the accessory drive components for turning smoothly. Also test the
accessory drive components with the engine operating by varying the load on the components to verify
that the components operate properly.
5: This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not
operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which
could cause a squeal noise.
6: This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner
from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly
and may be turning an accessory drive component in the wrong direction.
outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves
across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the
proper installation procedure for that pulley.
8: This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle
compare the pulley sizes.
14
Replacement.
Did you complete the repair? Go to Step 15
Go to Diagnostic
Aids
15
Operate the system in order to verify the repair.
Did you correct the condition? System OK Go to Step 3
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Drive Belt Squeal Diagnosis
DRIVE BELT WHINE DIAGNOSIS
Diagnostic Aids
The drive belt will not cause the whine noise.
If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure
Step Action Yes No
DEFINITION: The following items are indications of drive belt squeal:
 A loud screeching noise that is caused by a slipping drive belt.
 The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning
compressor engagement snapping the throttle, or slipping on a seized pulley or a faulty accessory
drive component.
NOTE:
Refer toBELT DRESSING NOTICE in Cautions and Notices.
1
operation and perform the necessary inspections? Go to Step 2
Go to Symptoms -
Engine Mechanical
2
Verify that there is a squeal noise.
Does the engine make the squeal noise? Go to Step 3
Go to Diagnostic
Aids
3
Replacement.
seconds.
Does the noise still exist?
Go to Engine Noise
Diagnosis Go to Step 4
4
Inspect for an accessory drive component seized
bearing or a faulty accessory drive component.
Did you find and correct the condition? Go to Step 9 Go to Step 5
5
Test the drive belt tensioner for proper operation. Refer
to Drive Belt Tensioner Diagnosis.
6
Inspect for the correct drive belt length. Refer to Drive
Belt Replacement.
7
Inspect for misalignment of a pulley.
8
Inspect for the correct pulley size.
Did you find and correct the condition? Go to Step 9
Go to Diagnostic
Aids
9
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they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged,
the power steering system restricted or the wrong fluid, or the generator failing.
Test Description
3: This test is to verify that the noise is being caused by the drive belt or the accessory drive components.
When removing the drive belt the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belt removed.
4: The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings.
The drive belt may have to be installed and the accessory drive components operated separately by
varying their loads. Refer to the suspected accessory drive component for the proper inspection and
replacement procedure.
Drive Belt Whine Diagnosis
DRIVE BELT RUMBLING DIAGNOSIS
Step Action Yes No
DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component
failed bearing.
NOTE:
1
operation and perform the necessary inspections?
Go to Step 2
Go to Symptoms -
Engine
Mechanical
2
Verify that there is a whine noise.
Does the engine make the whine noise? Go to Step 3
Go to Diagnostic
Aids
3
Replacement.
seconds.
Does the whine noise still exist?
Go to Engine
Noise on Start-
Up, but Only
Lasting a Few
Seconds , Upper
Engine Noise,
Regardless of
Engine Speed ,
Lower Engine
Noise, Regardless
of Engine Speed ,
or Engine Noise
4
Inspect for a failed accessory drive component bearing.
Did you find and repair the condition? Go to Step 5
Go to Diagnostic
Aids
5
Did you correct the condition? System OK
-
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Diagnostic Aids
Vibration from the engine operating may cause a body component or another part of the vehicle to make
rumbling noise.
The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the
only repair for the symptom.
If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is
installed, there might be an accessory drive component with a failure. Varying the load on the different
accessory drive components may aid in identifying which component is causing the rumbling noise.
Test Description
2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may
cause a similar symptom.
3: This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused
with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time
if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be
operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive
belt removed.
4: Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of
the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and
may be seen at the edge of the belt our felt as a lump in the belt.
5: Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt
does not have a smooth surface for proper operation.
Drive Belt Rumbling Diagnosis
Step Action Yes No
DEFINITION:
 A low pitch tapping, knocking, or thumping noise heard at or just above idle.
 Heard once per revolution of the drive belt or a pulley.
 Rumbling may be caused from:
 Pilling, the accumulation of rubber dust that forms small balls or strings in the drive belt
pulley groove
 The separation of the drive belt
 A damaged drive belt
NOTE:
Go to Symptoms -
2003 Saturn L200
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DRIVE BELT VIBRATION DIAGNOSIS
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C
system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the
generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive
components.
Test Description
1
Go to Step 2
Engine
Mechanical
2
Verify that there is a rumbling noise.
Does the engine make the rumbling noise? Go to Step 3
Go to Diagnostic
Aids
3
Replacement.
seconds.
Does the rumbling noise still exist?
Go to Engine
Noise on Start-
Up, but Only
Lasting a Few
Seconds , Upper
Engine Noise,
Regardless of
Engine Speed ,
Lower Engine
Noise, Regardless
of Engine Speed ,
or Engine Noise
4
Inspect the drive belt for damage, separation, or sections
of missing ribs.
Did you find any of these conditions? Go to Step 7 Go to Step 5
5
Inspect for severe pilling of more than 1/3 of the drive
belt pulley grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
6
1. Clean the drive belt pulleys using a suitable wire
brush.
2. Reinstall the drive belt. Refer to Drive Belt
Replacement.
7
Install a new drive belt. Refer to Drive Belt
Replacement.
Did you complete the replacement? Go to Step 8 -
8
Did you correct the condition? System OK
Go to Diagnostic
Aids
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2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may
cause a similar symptom such as the exhaust system, or the drivetrain.
3: This test is to verify that the drive belt or accessory drive components may be causing the vibration.
When removing the drive belt the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belt removed.
4: The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the
condition of the belt.
installed.
8: This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan
for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect
for a bent fan shaft or bent mounting flange.
9: This step should only be performed if the water pump is driven by the drive belt. Inspect the water
pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play.
Compare the water pump with a known good water pump.
10: Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that
accessory component causing it to vibrate.
Drive Belt Vibration Diagnosis
Step Action Yes No
DEFINITION: The following items are indications of drive belt vibration:
 The vibration is engine-speed related.
 The vibration may be sensitive to accessory load.
NOTE:
1
Go to Step 2
Go to Symptoms -
Engine
Mechanical
2
Verify that the vibration is engine related.
Does the engine make the vibration? Go to Step 3
Go to Diagnostic
Aids
3
Replacement.
seconds.
Does the engine still make the vibration?
Go to Diagnostic
Starting Point -
Vibration
Diagnosis and
Correction in
Vibration
Diagnosis and
Correction Go to Step 4
4
Inspect the drive belt for wear, damage, debris build-up
and missing drive belt ribs.
2003 Saturn L200
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DRIVE BELT FALLS OFF DIAGNOSIS
Diagnostic Aids
If the drive belts repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied or released by an accessory drive component may cause the drive belt to
fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.
Test Description
2: This inspection is to verify the condition of the drive belt. Damage to the belt may have occurred when
it came off of the pulleys. The drive belt may have been damaged, which caused the drive belt to fall off.
Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves
across 2 or 3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the
5
Replacement.
Did you complete the replacement? Go to Step 11 -
6
7
1. Tighten any loose fasteners.
2. Replace improper or missing fasteners. Refer to
Fastener Tightening Specifications.
Did you complete the repair? Go to Step 11 -
8
Inspect for damaged fan blades or bent fan clutch shaft, if
the fan is belt driven.
9
Inspect for a bent water pump shaft, if the water pump is
belt driven. Refer to Water Pump Replacement (L61) or
Water Pump Replacement (L81) in Engine Cooling.
10
Inspect for bent or cracked brackets.
Did you find and correct the condition? Go to Step 11
Go to Diagnostic
Aids
11
2003 Saturn L200
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proper installation procedure for that pulley.
5: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the
pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the
smooth surface of a pulley when the back side of the belt is used to drive the pulley.
6: Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving
under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
Drive Belt Falls Off Diagnosis
Step Action Yes No
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
NOTE:
1
Go to Step 2
Go to Drive Belt
Tensioner
Diagnosis
2
Inspect for a damaged drive belt.
3
Replacement.
Does the drive belt continue to fall off? Go to Step 4 System OK
4
Inspect for misalignment of the pulleys.
Did you find and repair the condition? Go to Step 12 Go to Step 5
5
Inspect for a bent or dented pulley.
6
Inspect for a bent or a cracked bracket.
7
Did you find loose or missing fasteners? Go to Step 8 Go to Step 9
8
 Tighten any loose fasteners.
 Replace improper or missing fasteners. Refer to
FASTENERS in General Information.
9
Test the drive belt tensioner for operating correctly.
Refer to Drive Belt Tensioner Diagnosis.
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
10
Replace the drive belt tensioner. Refer to Drive Belt
Tensioner Diagnosis.
Inspect for failed drive belt idler and drive belt
2003 Saturn L200
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DRIVE BELT EXCESSIVE WEAR DIAGNOSIS
Fig. 19: Minor Cracks DO NOT Warrant Drive Belt Replacement
Minor cracks in the belt rib are normal. They are the result of reverse bending around a backside pulley. Do not
replace belts for minor cracks.
11
tensioner pulley bearings.
Did you find and repair the condition? Go to Step 12
Go to Diagnostic
Aids
12
2003 Saturn L200
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2003 Saturn L200
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Fig. 20: Chunking, Cord Breakage Or Separation DO Warrant Drive Belt Replacement
Belts that have chunking longer than 5 mm (13/16 in) in one or more places should be replaced.
Belts should also be replaced if cord breakage or fabric separation is observed.
DRIVE BELT TENSIONER DIAGNOSIS
Tools Required
SA9181NE Belt Tension Gage
Belt and Tensioner Load Inspection
2003 Saturn L200
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Fig. 21: Drive Belt Routing Illustration
1. The following procedure is to be used when the belt or tensioner is suspected of allowing pulleys to slip
or causing any unusual belt noises.
1. Warm up the engine for approximately 10 minutes with all accessories turned ON.
2. The steering wheel must be turned full left and right several times, if equipped with power steering.
2003 Saturn L200
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Fig. 22: Using 15 mm Wrench To Rotate Tensioner Pulley
2. Shut the engine OFF.
3. Using a 15 mm wrench, rotate the tensioner arm clockwise until the belt becomes loose on the pulleys.
Slowly allow the tensioner to apply tension back on the belt.
2003 Saturn L200
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Fig. 23: View of Tensioner Pulley
4. The tensioner pulley must not be allowed to snap against the belt.
IMPORTANT: The marking on the tensioner arm must fall within the operating range (2
marks) on the tensioner body. If the tensioner marks fall outside the
operating range, the accessory drive belt must be replaced.
2003 Saturn L200
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Fig. 24: Checking Belt Tension
5. Using a calibrated SA9181NE , or equivalent, (OTC® OEM 1294), read and record the belt tension at
mid span for the following drive combinations. This check can be performed on an engine assembly
removed from the vehicle. It can not be performed with the engine in the vehicle unless the upper engine
mount is removed.
6. Repeat steps 2 and 5 three times and record the information.
2003 Saturn L200
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Fig. 25: Belt Tensioner Chart
7. Add the 3 readings together and divide the total by 3, as shown in the example:
 Belt Tension = Readings / (# of readings)
 Belt Tension = [(1)+(2)+(3)] / 3
 Example: (54 + 58 + 52) = 164 / 3
 Belt Tension = 55 lb.
8. Refer the belt tension chart for specifications.
Accessory Drive Belt Inspection
2003 Saturn L200
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2003 Saturn L200
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Fig. 26: Chunking, Cord Breakage Or Separation DO Warrant Drive Belt Replacement
1. Minor cracks in the belt rib are normal. They are the result of reverse bending around a backside pulley.
Do not replace belts for minor cracks.
Belts that have chunking longer than 5 mm (13/16 in) in one or more places should be replaced.
Fig. 27: Minor Cracks DO NOT Warrant Drive Belt Replacement
2. Belts should also be replaced if cord breakage or fabric separation is observed.
2003 Saturn L200
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REPAIR INSTRUCTIONS
DRIVE BELT REPLACEMENT
Removal Procedure
Fig. 28: Removing & Installing Engine Mount Bracket
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure
in Battery.
IMPORTANT: The engine must be supported upon removal of the engine mount.
2003 Saturn L200
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2. Remove the right front engine mount and engine mount bracket from the engine block. Refer to Engine
Mount Replacement.
Fig. 29: Using 15 mm Wrench To Rotate Tensioner Pulley
3. Use a 15 mm wrench to rotate the tensioner pulley clockwise while sliding the drive belt off the tensioner
or water pump pulley.
4. Remove the drive belt.
5. Clean and inspect the serpentine drive belt surfaces.
Installation Procedure
2003 Saturn L200
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Fig. 30: Drive Belt Routing Illustration
1. Route the belt around all pulleys, except the tensioner or water pump.
2. Use a 15 mm wrench to rotate the tensioner pulley clockwise.
3. Slip the belt over the idler or water pump pulley.
4. Install the right front engine mount. Refer to Engine Mount Replacement.
IMPORTANT: Ensure that the drive belt is aligned into the proper grooves on the drive
pulley.
2003 Saturn L200
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5. Connect the negative battery cable.
Tighten: Tighten the battery terminal bolts to 17 N.m (13 lb ft).
ENGINE MOUNT INSPECTION
1. Install the engine support fixture.
2. Observe the engine mount while raising the engine. Raising the engine removes the weight from the
engine mount and creates slight tension on the rubber.
3. Replace the engine mount if the engine mount exhibits any of the following conditions:
 The hard rubber is covered with heat check cracks.
 The rubber is separated from the metal plate of the engine mount.
 The rubber is split through the center of the engine mount.
 The engine mount itself is leaking fluid.
4. For engine mount replacement. Refer to Engine Mount Replacement.
DRIVE BELT TENSIONER REPLACEMENT
Removal Procedure
IMPORTANT: Before replacing any engine mount due to suspected fluid loss, verify that
the source of the fluid is the engine mount, not the engine or accessories.
2003 Saturn L200
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Fig. 31: Using 15 mm Wrench To Rotate Tensioner Pulley Clockwise
1. Use a 15-mm wrench to rotate the tensioner pulley clockwise while lifting the drive belt off the idler
pulley.
2. Raise the vehicle.
IMPORTANT: Complete accessory drive belt removal is not required for tensioner
replacement.
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Fig. 32: Removing & Installing Accessory Drive Belt Tensioner Assembly (L81 V6 Only)
3. Remove the drive belt tensioner bolts.
4. Remove the drive belt tensioner from the engine.
2003 Saturn L200
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Fig. 33: Removing & Installing Accessory Drive Belt Tensioner Assembly (L81 V6 Only)
1. Install the drive belt tensioner to the engine.
2. Install the drive belt tensioner bolts.
Tighten: Tighten the belt tensioner bolts to 40 N.m (30 lb ft).
3. Lower the vehicle.
2003 Saturn L200
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Fig. 34: Using 15 mm Wrench To Rotate Tensioner Pulley Clockwise
4. Route the drive belt around all pulleys except the idler or water pump pulley.
5. Use a 15-mm wrench to rotate the tensioner pulley clockwise.
6. Slip the drive belt over the idler or water pump pulley.
INTAKE RUNNER REPLACEMENT (FRONT)
IMPORTANT: Ensure that the drive belt is aligned into the proper grooves on the drive
pulleys.
2003 Saturn L200
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Tools Required
J 43914 Universal Clamp Pliers
Removal Procedure
Fig. 35: Removing/Installing Intake Hose Assembly
1. Disconnect the negative battery cable.
2. Remove the intake hose assembly.
2003 Saturn L200
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Fig. 36: Removing Intake Runner Rubber Boot Hose Clamps
3. Remove 4 rubber boot hose clamps using the J 43914 .
IMPORTANT: Clamps are reusable if not damaged. Do not discard.
2003 Saturn L200
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Fig. 37: Removing & Installing Front Intake Manifold Runner
4. Remove the intake runner mounting bolts.
5. Disconnect the intake runner from the rubber boots and remove the intake runner.
2003 Saturn L200
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Fig. 38: Removing & Installing Front Intake Manifold Runner
1. Install the intake runner onto the rubber boots.
2. Install the intake runner mounting bolts.
Tighten: Tighten the intake manifold runner bolts to 8 N.m (71 lb in).
2003 Saturn L200
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Fig. 39: Installing Intake Runner Rubber Boot Hose Clamps
3. Install the 4 rubber boot hose clamps using the J 43914 .
IMPORTANT: Inspect the hose clamps for damage. Replace if damaged.
2003 Saturn L200
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4. Install the hose assembly.
5. Connect the negative battery cable.
Tighten: Tighten the battery terminal bolts to 17 N.m (13 lb ft).
INTAKE RUNNER REPLACEMENT (REAR)
Tools Required
J 43914 Universal Clamp Pliers
2003 Saturn L200
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Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the intake hose assembly.
2003 Saturn L200
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Fig. 42: Removing & Installing ECM Electrical Connectors
3. Remove the ECM electrical connectors.
4. Remove the ECM bolts and the ECM.
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Fig. 43: Removing Intake Runner Rubber Boot Hose Clamps
5. Remove the 4 rubber boot hose clamps using the J 43914 .
IMPORTANT: Clamps are reusable if not damaged. Do not discard.
2003 Saturn L200
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Fig. 44: Removing & Installing Threaded Brake Vacuum Hose
6. Disconnect the threaded brake vacuum hose.
2003 Saturn L200
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Fig. 45: Connecting Intake Plenum Switch-Over Valve Vacuum Hose At Switch-Over Valve
7. Disconnect the intake plenum switch-over valve vacuum hose at the switch-over valve. Note the hose
routing.
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Fig. 46: Removing & Installing Rear Intake Manifold Runner
8. Remove the intake runner mounting bolts.
9. Disconnect the vent hose from the throttle body.
10. Disconnect the intake runner from the rubber boots and remove the intake runner. Note the throttle body
vent hose routing.
2003 Saturn L200
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Fig. 47: Removing & Installing Rear Intake Manifold Runner
1. Install the intake runner onto the rubber boots.
2. Route the throttle body vent hose under the vacuum reservoir and connect to the throttle body.
3. Install the intake runner mounting bolts.
Tighten: Tighten the intake manifold runner bolts to 8 N.m (71 lb in).
2003 Saturn L200
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