Engine Valve Cover Gasket Set Guide for the 2005-2007 Saturn Relay
Stop oil leaks and burning smells by choosing the right valve cover gasket set for your Relay's specific V6 engine.
- You MUST confirm if your Relay has the 3.5L or 3.9L V6 engine before ordering, as the parts are different.
- A burning oil smell is the most common symptom and indicates oil is leaking onto the hot exhaust, which can be a fire risk.
- The rear valve cover is much harder to replace than the front, which is why professional labor costs can be high.
- Premium aftermarket brands like Fel-Pro and Victor Reinz offer excellent, reliable seals without the high cost of OEM parts.
Understanding Your Saturn Relay's Engine
Before buying a valve cover gasket set, you must know which engine your 2005-2007 Saturn Relay has. This is the most common mistake owners make. The gaskets are not interchangeable.
- 2005-2006 Models: Most of these vans came with a 3.5L V6 engine.
- 2006-2007 Models: A 3.9L V6 engine became available in 2006 and was standard by 2007.
Pro Tip: Check the emissions sticker under your hood or the owner's manual to confirm your engine size before ordering parts.
Symptoms of a Leaking Valve Cover Gasket
A failing valve cover gasket is a common issue as a vehicle ages. The rubber becomes hard and brittle from engine heat cycles and can no longer create a proper seal. Here are the signs to look for:
- Burning Oil Smell: This is the most common symptom. Oil leaks from the valve cover and drips onto the hot exhaust manifold, creating a distinct and unpleasant burning smell.
- Visible Oil Leaks: You may see wet, oily patches on the top or sides of the engine. Oil attracts dirt, so look for areas of dark, grimy buildup on the valve covers.
- Low Engine Oil: A significant leak will cause your engine oil level to drop over time, forcing you to top it off between oil changes.
- Oil in Spark Plug Wells: If the spark plug tube seals fail, oil can pool around the spark plugs, which can cause misfires or other ignition problems.
A Note on GM Recalls
While not for the 3.9L engine in the Relay, a notable GM recall (15757) existed for older 3.8L V6 engines due to a fire risk from oil leaking from the front valve cover gasket onto the exhaust. This history highlights the importance of addressing any oil leak promptly, no matter how small it seems.
Choosing the Right Aftermarket Gasket Set
For a vehicle like the Saturn Relay, aftermarket gaskets offer excellent quality, often meeting or exceeding original equipment (OE) specifications. You don't need to pay dealership prices for a reliable seal.
- Premium Brands (Fel-Pro, Victor Reinz): These are top-tier aftermarket brands trusted by professional mechanics. Fel-Pro is a long-standing leader in gaskets, known for quality materials. Victor Reinz is often an original equipment supplier to car manufacturers and is praised for its soft, pliable rubber gaskets that seal well. You can't go wrong with either of these brands for a durable, long-lasting repair.
- Standard Brands (Apex): Brands like Apex offer a more budget-friendly option. While they can provide a good seal, they may not have the same longevity or advanced materials as the premium brands. They are a viable choice for a vehicle with high mileage or if budget is the primary concern.
Replacement Cost and Difficulty
Replacing the valve cover gaskets on the Saturn Relay's V6 engine is a tale of two halves. The front gasket (closest to the radiator) is relatively easy to access. The rear gasket (against the firewall) is significantly more difficult and time-consuming to reach, often requiring the removal of other components. This dramatically impacts labor costs if you take it to a shop.
| Item | Estimated Cost |
|---|---|
| New Aftermarket Gasket Set | $17 - $41 |
| Shop Labor | $400 - $600+ |
| Total Professional Installation | $450 - $700+ |
Frequently Asked Questions
Is this a DIY-friendly job?
For an experienced DIY mechanic, yes. However, due to the difficult access to the rear valve cover, it can be a frustrating job. The front cover is much easier. If you are not comfortable working in tight spaces, it may be best to leave this to a professional.
What happens if I don't replace a leaking gasket?
Ignoring the leak can lead to several problems. A continuous loss of oil can cause severe engine damage if the level gets too low. Oil leaking onto the alternator can cause it to fail. Most importantly, oil dripping onto a hot exhaust creates a significant fire hazard.
Should I use sealant on the new gasket?
Most modern rubber gaskets are designed to be installed dry. However, a small dab of RTV sealant is typically required at the corners or "T-joints" where the engine block, cylinder head, and timing cover meet. Always follow the instructions included with your specific gasket set.
Do I need to replace the valve cover bolts?
Usually, no. However, the new gasket set should come with new rubber grommets for the bolts. These grommets harden and leak over time just like the main gasket, so they should always be replaced.
Technical Specifications
Fits 2005-2007 Saturn Relay with either the 3.5L V6 or 3.9L V6 engine. Set typically includes valve cover gaskets, spark plug tube seals, and bolt grommets.
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The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
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