Engine - Rear Main Seal Replacement
Number: 84-78Section: 6A (VI)
Date: Feb., 1984
Subject: REAR MAIN SEAL REPLACEMENT FOR 2.0L L4 ENGINE
Model and Year: 1984-1/2 CAVALIER AND "S/T"
TRUCK LQ5, LQ2 AND LR9
TO: ALL CHEVROLET DEALERS
In December, 1983, a new "thick" rear main seal went into production in 1984-1/2 Cavalier and "S/T" trucks with 2.0L L4, LQ5, LQ2 and LR9 engines.
New rear seal -- starting VIN's:
Lordstown December 5, 1983
Chevrolet 1G1AD69P8E7141224
Janesville December 12, 1983
Chevrolet 1G1AE77P5EJ172567
Vehicles assembled after the VIN's shown above will have engines with this new seal. (Note: verification of the block casting identifier is recommended).
This new seal is sold as part of service kit, P/N 14085829.
FIGURE 1 - Identification Mark:
Before replacing a rear main seal, care should be taken in determining the exact source of leak. If it has been determined that the rear main oil seal is the cause of the leak, it will be necessary to identify the type of seal required to service the engine. Refer to Figure 1 for the identification mark.
If it is determined that a rear main seal replacement is required, use the following procedure. (Note: replacement of this new seal under warranty will require zone authorization):
1. Support engine.
2. Remove transmission as outlined in the transmission section of the shop manual.
3. Remove flywheel. At this time, check to confirm rear seal leak.
FIGURE 2 - Dust Lip:
4. Remove seal by inserting a screwdriver or similar tool in through the dust lip at an angle as shown in Figure 2. Pry seal out by moving handle of screwdriver towards the end of the crankshaft pilot. Repeat as required around the seal until seal is removed. Care must be taken not to damage crankshaft O.D. surface.
FIGURE 3 - Seal Installation With J34686:
5. Check I.D. of bore for knicks or burrs and correct as required. Inspect crankshaft for burrs or nicks on surface which contacts seal. Repair or replace crankshaft as required.
6. Install new seal using tool J-34686 (Figure 3).
FIGURE 4 - Seal Installation Over Mandril:
7. Install seal over mandril, slide the seal on the mandril until dust lip (back of seal) bottoms squarely against collar of tool (Figure 4).
8. Align dowel pin of tool with dowel pin hole in crankshaft and attach tool to crankshaft by hand, or torque attaching screws to 2-5 ft.lbs.
9. Turn "T" handle of tool so that collar pushes seal into the bore, turn handle until the collar is tight against case. This will insure the seal is seated properly.
10. Loosen the "T" handle of the tool until it comes to a stop. This will insure that the collar will be in the proper position for installing a new seal. Remove attaching screws.
11. Check seal, making sure seal is seated squarely in bore.
12. Install flywheel.
13. Start engine, check for leaks.
14. Install transmission.
Use applicable labor operations.