How do you replace the head gasket located on a 1997 Saturn SL2?

Answer 1

It will probably be best to remove the engine since you need to also remove the timing chain, and that means removing the dampener pulley and the front cover/oil pump.

The worst part of removing the engine, is remembering where everything goes when you put it all back together. Drain fluids, remove the radiator fan shroud, fan and radiator. Remove the transmission dust cover (under the vehicle, between the engine and transmission. If it's an automatic, disconnect the torque converter from the flex plate, then disconnect the bell-housing from the engine block. If it's a stick shift it might be easier to remove the entire engine/transmission as an assembly.

Remove the drivers side front wheel then remove the wheel well dust cover to get access to the serpentine belt tensioner. Remove the serpentine belt, lift the Power Steering pump to the side. Disconnect the exhaust line, fuel line, all electrical connections (make sure you know where they go so you can put them back), lift the AC compressor to the side.

Attach an engine lift to take the weight of the engine, then remove the motor mounts and lift the engine out.

Pull the dampener pulley, valve cover, front cover of the engine and loosen the timing chain sprockets, on the crankshaft and on the camshafts(2 on the SL2), but don't remove the chain yet. Retract the hydraulic chain tensioner piston assembly and hold it in place using a small drill bit or a piece of clean wire through the hole. Note that there is a release lever that allows the tensioner to be retracted. Remove the timing chain tensioner rails ONLY AFTER you have retracted the chain tensioner piston assembly.

Remove the timing chain and tensioner rails.

If you haven't done so already, remove the intake and exhaust manifolds as well as the EGR valve. Once the timing chain has been removed you can remove the head. Remove the 10 head bolts and the head should lift out, although the gasket may stick a little since it's been there for over 14 years. DON'T pry it off, just work with it until it's free.

Take the head to a qualified machine shop and have the head resurfaced. It would be a good idea to have the valves and guides done at the same time.

Get the torque sequence and torque wrench values from the machine shop when you pick up the head.

Reassemble the engine in the reverse order, using new gaskets and new timing chain and sprockets.

Next time, don't let the engine overheat and the head gasket should never fail.