Info - Limited Service Repair Program for the 3.5L V-6 Engine Assembly (RPO L66)
| Subject: | Limited Service Repair Program for the 3.5L V-6 Engine Assembly (RPO L66) |
| Models: | 2004- 2005 Saturn VUE Vehicles) |
| with 3.5L V-6 Engine (VIN 4 -- RPO L66 |
| Attention: | Fixed Operations Manager and Technician |
This bulletin is being revised to add the 2005 model year. Please discard Corporate Bulletin Number 03-06-01-026 (Section 06 -- Engine).
Purpose
The purpose of this bulletin is to outline the level of service for 2004 and 2005 Saturn VUE vehicles equipped with the 3.5L V-6 engine (RPO L66).
The Limited Service Repair Program will be used to provide quick and reliable product feedback that product engineering will use to identify and resolve product concerns.
Important: To facilitate effective engineering analysis, do not disassemble or loosen any fasteners of the removed short block or cylinder head assemblies. Also, be sure to completely fill out the Core Return Tag (item # S0399300) before returning any engine short block or cylinder head assembly to the SSPO Core Return Center (in Canada, use the normal core return process to return to your servicing PDC).
AUTHORIZED 3.5L V-6 (RPO L66) ENGINE COMPONENT REPAIRS
Currently, authorized repairs on the 3.5L V-6 (RPO L66) engine assembly include all components excluding the short block and cylinder head assemblies. If any internal component of the 3.5L V-6 (RPO L66) short block or cylinder head assemblies require repair or replacement, the complete short block or cylinder head must be replaced as an assembly. If any of the component parts of the short block or cylinder head listed below require replacement, install a new assembly. All other components are fully serviceable.
SHORT BLOCK
Block, Crankshaft and Connecting Rod Bearings, Connecting Rods, Pistons, Piston Rings, Oil Flow Control Module.
CYLINDER HEAD
Valve Guides, Valve Seats, Valve Seals, Valve Springs, Valve Spring Retaining Components, Valve Lash Adjusters, Camshafts, Rocker Arm Assemblies.
Important: Do not remove any unauthorized components from the engine short block or cylinder head assemblies. Do not remove/replace any unauthorized fasteners from the engine short block assembly as the fastener torque data may assist in determining the cause of the malfunction.
FLUID LEAK (S)
- Verify the fluid leak is actually engine oil or coolant. Refer to "Oil Leak Diagnosis" (SI Document ID #1314600) in the Engine Mechanical section of the 2004 or 2005 Saturn VUE Engine (L66) Service Manual.
- Be sure to mark the exact location of the leak(s) on the short block assembly with a permanent marker or paint stick.
INTAKE MANIFOLD/UPPER ENGINE
500. Intake Manifold | 511. Gasket | 548. Positive Crankcase Ventilation (PCV) Hose | 715. Intake Air Temperature (IAT) Sensor |
501. Gasket | 512. Cover Top | 549. Clamp | 718. Evaporative Emission (EVAP) Valve |
502. Cover Side | 513. Bolt | 553. Stud | 719. Clamp |
503. Nut | 514. Nut | 554. Cap | 725. Hose |
504. Bolt/Stud | 515. Stud | 555. Bolt | 726. Hose |
505. Cover Side | 516. Stud | 708. Bolt | 727. Bolt |
506. Gasket | 517. Gasket | 709. Front Lift Bracket | 728. Dampener |
507. Nut | 518. Throttle Body | 711. Bolt | 729. Bolt |
508. Bolt | 519. Nut | 712. Manifold Absolute Pressure (MAP) Sensor |
|
509. Exhaust Gas Recirculation (EGR) Tube | 520. Gasket | 713. O-Ring |
|
510. Bolt | 521. Spacer | 714. O-Ring |
|
CYLINDER HEAD/UPPER ENGINE
Important: Ensure head gasket is returned with engine or cylinder head assembly.
COMPONENT PARTS SHOWN IN BOLD REQUIRE CYLINDER HEAD ASSEMBLY REPLACEMENT
200. Cylinder Head | 217. Nut | 410. Oil Filter | 541. Gasket |
201. Guide Intake | 218. Rocker Arm Exhaust | 429. Oil Level Indicator | 542. Cover |
202. Spring Seat-Intake | 219. Spring | 441. O-Ring | 543. Bolt |
203. Seal Intake | 220. Shaft Exhaust | 522. Fuel Feed Pipe | 544. Grommet |
204. Spring Intake | 221. Shaft Intake | 523. Fuel Rail with Injectors and Hoses | 545. Oil Filter Cap |
205. Cap Intake | 222. Valve Intake | 524. Bolt | 546. O-Ring |
206. Keys Intake | 223. Seal | 525. O-Ring | 547. Pin |
207. Valve Lash Adjuster | 225. Gasket | 526. Clip | 549. O-Ring |
208. Bolt | 226. Pin | 527. Fuel Injector | 551. Positive Crankcase Ventilation (PCV) Valve |
209. Camshaft | 263. Valve Exhaust | 528. O-Ring | 552. Bolt |
210. O-Ring | 264. Guide Exhaust | 530. Nut | 706. Spark Plug |
211. Cap | 265. Sprint Seat - Exhaust | 531. Manifold | 707. Ignition Coil |
212. Bolt | 266. Seal Exhaust | 532. Bolt | 708. Bolt |
213. Stud | 267. Spring Exhaust | 533. Gasket | 720. Knock Sensor |
214. Bolt | 268. Cap Exhaust | 534. Stud | 731. Bolt |
215. Rocker Arm Assembly Intake | 269. Keys Exhaust | 535. Stud |
|
216. Bolt | 270. Gasket | 540. Seal |
|
FRONT/REAR OF ENGINE
124. Crankshaft Rear Oil Seal | 235. Timing Belt | 247. Bolt | 262. Bolt |
125. Flywheel | 236. Guide | 248. Sprocket | 271. Label |
126. Washer | 237. Sprocket | 249. Bolt | 272. Seal |
127. Bolt | 238. Bolt | 250. Bolt | 410. Oil Filter |
227. Balancer Bolt with Washer | 239. Idler Pulley | 251. Bolt | 419. Seal |
228. Crankshaft Balancer | 240. Bolt | 252. Tensioner | 700. Camshaft Position (CMP) Sensor |
229. Cover Lower Front | 241. Sprocket | 256. Seal | 701. Harness |
230. Seal | 242. Bolt | 257. Cover Upper Front | 702. Nut |
231. Nut | 243. Seal | 258. Seal | 703. Guide |
232. Tensioner Pulley | 244. Cover Upper Rear | 259. Cover Upper Front | 704. Crankshaft Position (CKP) Sensor |
233. Tensioner Bracket | 245. Seal | 260. Grommet | 723. Bolt |
234. Tensioner Bushing | 246. Cover Upper Rear | 261. Bolt | 730. Bolt |
LOWER ENGINE ASSEMBLY
COMPONENT PARTS SHOWN IN BOLD REQUIRE SHORT BLOCK ASSEMBLY REPLACEMENT.
100. Engine Block | 116. Connecting Rod Cap | 126. Washer |
|
102. Crankshaft | 117. Bearing - Connecting Rod | 127. Bolt | 406. O-Ring |
103. Cap | 118. Connecting Rod | 128. Pin | 407. Bolt |
104. Bearing - Thrust | 119. Pin | 129. Pin | 408. Deflector |
105. Bearing - Main Upper | 120. Piston | 400. Oil Pan | 409. Bolt |
106. Bearing - Main Lower | 121. Clip | 401. O-Ring | 536. O-Ring |
107. Pin | 122. Piston Rings | 402. Pin | 537. Housing |
108. Bolt | 123. Key | 403. Drain Plug | 538. Bolt |
109. Bolt | 124. Seal | 404. Bolt | 539. Pin |
115. Bolt | 125. Flywheel | 405. Screen |
|
COOLING SYSTEM/EGR
110. Coolant Drain Plug | 305. Coolant Crossover Pipe | 311. Thermostat | 601. Exhaust Gas Recirculation (EGR) Valve |
111. Coolant Drain Fitting | 306. Gasket | 312. O-Ring | 602. Gasket |
112. Washer | 307. Gasket | 313. Housing | 603. Stud |
113. Coolant Drain Plug | 308. Housing | 314. Bolt | 716. O-Ring |
114. Washer | 309. Nut | 410. Oil Filter | 717. Coolant Temperature Sensor (CTS) |
304. O-Ring | 310. Bolt | 600. Nut | 720. Knock Sensor |
REMOVAL AND INSTALLATION PROCEDURE
Refer to the engine short block and cylinder head removal and installation procedures in the 2004 or 2005 Saturn VUE Engine (L66) Service Manual.
SHIPPING PREPARATION
- Place removed engine short block or cylinder head core into the original shipping container. Be sure that all coolant and oil is properly drained from core, and drain plugs are replaced. Place the drained core into the new plastic bag provided and then carefully place the bagged engine core in the shipping container.
- Complete and attach the Core Return Tag (item # S0399300) to the engine short block or cylinder head core. Completely fill in the following information: core part number, retailer code, CSO number, and last eight (8) digits of the vehicle identification number (VIN). Retailers will NOT receive credit for returned cores if the Core Return Tag has not been completed.
- Secure the engine core to the container base with the enclosed adjustable strap or metal straps as received in the original packaging.
- Secure the wood top to the original shipping container.
- Return the engine core as soon as possible to SSPO Core Return Center, Spring Hill, TN (in Canada, use the normal core return process to return to your servicing PDC).
Important: NO credit will be provided for incorrect, incomplete or disassembled engine cores. Engine core damage caused as a result of collision, fire, flood, or misuse is not eligible to participate in this program.
SHIPPING INSTRUCTIONS
Core returns are to be shipped to the SSPO Core Return Center, Spring Hill, TN (in Canada, use the normal core return process to return to your servicing PDC) upon completion of repair. U.S. retailers, please refer to "Special Transactions" in the Saturn Parts Policies and Procedures Manual for core return process information.
Claim Information
To receive credit for any repairs during the warranty coverage period, submit a claim through the Saturn Dealer System, or if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.
Labor Operation | Labor Time |
|---|---|
J0152 | SPACER, INTAKE - REPLACE |
J0194 | COVER, UPPER INTAKE MANIFOLD--REPLACE |
J0250 | MANIFOLD INTAKE --REPLACE |
J0251 | GASKET, INTAKE MANIFOLD REPLACE |
J0258 | MANIFOLD INTAKE LOWER REPLACE |
J0259 | GSKT INTAKE MANIFOLD LOWER REPLACE |
J0310 | COVER/GASKET, R-CAMSHAFT HSG-REPLACE |
J0311 | COVER/GASKET, L-CAMSHAFT HSG-REPLACE |
J0317 | COVER/GASKET, BOTH CAMSHAFT HSG-REPLACE |
J0500 | GASKET, R-BANK CYLINDER HEAD-REPLACE |
J0501 | GASKET, L-BANK CYLINDER HEAD-REPLACE |
J0507 | GASKET, BTH BANKS CYL HEAD--REPLACE |
J0510 | HEAD, RIGHT BANK CYLINDER-REPLACE |
J0511 | HEAD, LEFT BANK CYLINDER-REPLACE |
J0517 | HEAD, BOTH BANKS CYLINDER-REPLACE |
J0340 | ROCKER ARM INTAKE RIGHT (REAR) HEAD--REPLACE |
J0341 | ROCKER ARM, INTAKE LEFT (FRONT) HEAD--REPLACE |
J0342 | ROCKER ARM EXHAUST RIGHT (REAR) HEAD--REPLACE |
J0343 | ROCKER ARM, EXHAUST LEFT (FRONT) HEAD--REPLACE |
J0519 | VALVES, ADJUST |
J0520 | VALVES ONE CYL * RIGHT BANK - RECONDITION OR REPLACE |
J0521 | VALVES ONE CYL * LEFT BANK - RECONDITION OR REPLACE |
J0527 | VALVES, ONE CYLINDER, BOTH BANKS- RECONDITION OR REPLACE |
J0540 | SPRING, CAP AND/OR SEAL, VALVE ONE CYL * RIGHT BANK - REPLACE |
J0541 | SPRING, CAP AND/OR SEAL, VALVE ONE CYL * LEFT BANK - REPLACE |
J0547 | SPRING, CAP AND/OR SEAL, VALVE ONE CYL * BOTH BANKS - REPLACE |
J0667 | BELT, SERPENTINE DRIVE - REPLACE |
J0684 | PULLEY ASSY, SERP BELT TENSION-REPLACE |
J0686 | BRACKET,TIMING BELT TENSIONER-REPLACE V |
J0720 | BALANCER, HARMONIC-REPLACE |
J0794 | SEAL, FRT CRANKSHAFT OIL-REPLACE |
J0800 | BELT, CAMSHAFT DRIVE-REPLACE |
J0808 | COVER,CAMSHAFT DRIVE BELT-FRONT-REPLACE |
J0815 | TENSIONER, TIMING BELT - REPLACE |
J0816 | PULLEY, TIMING BELT IDLER-REPLACE V |
J0830 | GEAR, CRANKSHAFT TIMING-REPLACE |
J0840 | GEAR, CAMSHAFT TIMING-REPLACE |
J0850 | CAMSHAFT - REPLACE |
J0852 | SEAL, ONE SEAL, RIGHT (REAR) BANK, CAMSHAFT - REPLACE |
J0853 | SEAL, ONE SEAL, LEFT (FRONT) BANK, CAMSHAFT - REPLACE |
J0930 | TUBE, OIL LEVEL INDICATOR - REPLACE |
J0950 | FILTER, OIL - REPLACE |
J0990 | PLUG AND/OR GASKET, OIL PAN DRAIN - REPLACE |
J0973 | SOLENOID, VTEC CONTROL - REPLACE |
J0974 | MODULE, VTEC OIL FLOW CONTROL - REPLACE |
J0975 | SWITCH, VALVE TIMING PRESSURE - REPLACE |
J1000 | PAN/GASKET, OIL-REPLACE |
J1005 | BAFFLE, OIL PAN - REPLACE |
J1020 | PUMP, ENGINE OIL-REPLACE |
J1060 | PICKUP TUBE AND SCREEN-REPLACE |
J1120 | SEAL, CRANKSHAFT REAR MAIN - REPLACE |
J1400 | FLYWHEEL (AUTOMATIC TRANSAXLE) - REPLACE |
J1493 | BRACKET, ENGINE MOUNT MIDRAIL - REPLACE |
J1498 | BRACKET, ENGINE MOUNT-FRNT-REPLACE |
J1500 | MOUNT, RIGHT FRONT ENGINE-REPLACE |
J1820 | BLOCK, PARTIAL/ BASIC - REPLACE |
J3480 | PUMP/GASKET, COOLANT-REPLACE |
J3500 | THERMOSTAT, OUTLET & GASKET-REPLACE |
J3513 | PIPE, WATER PUMP OUTLET - REPLACE |
J3520 | HOUSING AND/OR GASKET, THERMOSTAT - REPLACE |
J3527 | HOUSING &/OR SEAL, WATER CROSSOVER-REPLACE |
J4100 | GENERATOR ASSEMBLY-REPLACE |
J4217 | SPARK PLUG - DIAGNOSTICS WITHOUT REPLACEMENT |
J4226 | PLUGS, SPARK, ONE OR TWO- REPLACE |
J4340 | MODULE, IGNITION - REPLACE |
J4350 | SENSOR, CAMSHAFT - REPLACE |
J4355 | SENSOR, CRANKSHAFT - REPLACE |
J4437 | SENSOR, ELEC SPARK CNTRL KNOCK-REPLACE |
J4640 | MOTOR ASSEMBLY, STARTER - REPLACE |
J5020 | DUCT AND/OR HOSE, OUTSIDE AIR - REPLACE |
J5490 | BODY UNIT, THROTTLE-REPLACE |
J5650 | INJECTOR, FUEL - REPLACE |
J5660 | RAIL, FUEL - REPLACE |
J6200 | SENSOR, AIR CLEANER TEMPERATURE-REPLACE |
J6270 | VALVE/GASKET, EGR-REPLACE |
J6360 | CONTROLLER, VCM/ECM - REPLACE |
J6368 | COOLANT TEMPERATURE SENSOR-REPLACE |
J6370 | MANIFOLD ABSLT PRESSURE SENSOR-REPLACE |
J6372 | SENSOR, EXHAUST OXYGEN - REPLACE |
J6380 | SENSOR, HEATED OXYGEN (EXHAUST PIPE UNIT) - REPLACE |
J6441 | VALVE, CANISTER VENT SOLENOID-REPLACE |
