A method for forming a CMOS device in a manner so as to avoid dielectric
layer undercut during a pre-silicide cleaning step is described. During
formation of CMOS device comprising a gate stack on a semiconductor
substrate surface, the patterned gate stack including gate dielectric
below a conductor with vertical sidewalls, a dielectric layer is formed
thereover and over the substrate surfaces. Respective nitride spacer
elements overlying the dielectric layer are formed at each vertical
sidewall. The dielectric layer on the substrate surface is removed using
an etch process such that a portion of the dielectric layer underlying
each spacer remains. Then, a nitride layer is deposited over the entire
sample (the gate stack, the spacer elements at each gate sidewall, and
substrate surfaces) and subsequently removed by an etch process such that
only a portion of said nitride film (the "plug") remains. The plug seals
and encapsulates the dielectric layer underlying each said spacer, thus
preventing the dielectric material from being undercut during the
subsequent pre-silicide clean process. By preventing undercut, this
invention also prevents the etch-stop film (deposited prior to contact
formation) from coming into contact with the gate oxide. Thus, the
integration of thin-spacer transistor geometries, which are required for
improving transistor drive current, is enabled.