How to Repair a Head Gasket on a Saturn
- 1). Work on the Saturn vehicle when it is cold. Place a pan under the radiator to catch the coolant draining from the coolant system. Empty the engine oil. Relieve the pressure from the fuel lines. Take off the negative cable from the battery terminal.
- 2). Disassemble and lift out of the vehicle the upper engine car parts, including the hoses, wires, bolts, brackets and assemblies. Parts that need to come out of the car or disconnect from a car part include the vacuum hoses, ignition wires, spark plugs, accessory drive belts, exhaust manifold, intake manifold, timing chain and alternator.
- 3). Loosen the cylinder bolts in the correct sequence pattern. Consult a Saturn service manual to identify the correct sequence. Lift out the cylinder head. Inspect the cylinder head for leaks, dents, crack or other imperfection. Clean the cylinder head and gasket mating surface.
- 4). Install a new head gasket and line up the dowel pins. Use new cylinder bolts and tighten in the sequence for the particular Saturn vehicle. For instance, the torque specifications for the ION, L-Series or S-Series from 1999 to 2005 is 22 foot-pounds and add an extra 155 degrees. Torque the front cylinder bolts to 26 foot-pounds.
- 5). Replace the engine components back in the vehicle. Refill the engine oil reservoir and the coolant system. Prime the fuel lines by letting the engine run for five seconds and "Off" for 10 seconds. Start the engine and check. Connect the negative battery.
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