Answer

Engine Front Cover Replacement

Removal Procedure

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
4. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
5. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
6. Remove the power steering pump with lines. Move the power steering pump aside. Refer to Power Steering Pump Replacement in Power Steering.
7. Disconnect the thermostat bypass pipe from the engine front cover. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
8. Disconnect the radiator outlet hose from the coolant pump. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
9. Remove the coolant pump pulley. Refer to Water Pump Replacement in Engine Cooling.
   

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10. Remove the crankshaft position sensor wiring harness bracket from the engine front cover
    

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11. Remove the engine front cover bolts (1, 2 and 3).
12. Remove the engine front cover.
    

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13. Remove the engine front cover gasket.
14. Clean the engine front cover and engine block gasket sealing surfaces.
15. Inspect the engine front cover for damage to the engine front cover, crankshaft front oil seal or the gasket sealing surface.
    

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16. If replacing the engine front cover, remove the drive belt shield.
    

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17. If replacing the engine front cover, remove the crankshaft position sensor from the engine front cover. Refer to Crankshaft Position Sensor Replacement in Engine Controls.
18. If replacing the engine front cover, remove the coolant pump from the engine front cover. Refer to Water Pump Replacement in Engine Cooling.

Installation Procedure

1. If removed, install the coolant pump to the engine front cover. Refer to Water Pump Replacement in Engine Cooling.
   

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2. If removed, install the crankshaft position sensor to the engine front cover. Refer to Crankshaft Position Sensor Replacement in Engine Controls.
   

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3. If removed, install the drive belt shield.

   Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the drive belt shield bolt.

   Tighten
   Tighten the drive belt shield bolt to 10 N·m (89 lb in).

   
   

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5. Coat both sides of the lower tabs of the engine front cover gasket with sealant GM P/N XXXXXXX or equivalent.
   

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6. Install the engine front cover gasket.
   

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7. Install the engine front cover.
   

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8. Install the crankshaft position sensor wiring harness bracket to the engine front cover
9. Install the engine front cover bolts.

   Tighten

   •	Tighten the five small engine front cover bolts (1) to 21 N·m (15 lb ft).

   •	Tighten the three large engine front cover bolts (2) to 55 N·m (41 lb ft).

   •	Tighten the two large engine front cover bolts (3) to 47 N·m (35 lb ft).

10. Install the coolant pump pulley. Refer to Water Pump Replacement in Engine Cooling.
11. Connect the radiator outlet hose to the coolant pump. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
12. Connect the thermostat bypass pipe to the engine front cover. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
13. Install the power steering pump with lines. Refer to Power Steering Pump Replacement in Power Steering .
14. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
15. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
16. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
17. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
18. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
19. Camshaft Timing Chain and Sprocket Replacement

    Removal Procedure

    Tools Required

    J 5825-A Crankshaft Sprocket Remover

    1. Remove the engine front cover. Refer to Engine Front Cover Replacement .
       

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    2. Rotate the crankshaft until the timing marks in the following locations are aligned:

       •	The camshaft alignment pin (1).

       •	The timing chain dampener (2) to the crankshaft sprocket (3).

       •	The crankshaft key (4).

       •	The timing chain dampener (5) to the camshaft sprocket locator hole (6).

       
       

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    3. Remove the camshaft sprocket bolt.
       

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    4. Remove the camshaft sprocket.
       

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    5. Remove the timing chain.
       

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    6. Use the J 5825-A in order to remove the crankshaft sprocket.
       

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    7. Remove the timing chain dampener bolts.
    8. Remove the timing chain dampener.
       

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    9. If necessary remove the camshaft thrust plate bolts.
    10. Remove the camshaft thrust plate.

    Installation Procedure

    Tools Required

    J 38612 Crankshaft Sprocket Installer

    
    

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    1. If removed install the camshaft thrust plate.

       Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    2. Install the camshaft thrust plate bolts.

       Tighten
       Tighten the camshaft thrust plate bolts to 10 N·m (89 lb in).

       
       

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    3. Install the crankshaft sprocket using the J 38612 .
    4. Remove the J 38612 .
    5. Apply Engine Oil Supplement (EOS) GM P/N XXXXXXX or equivalent to the sprocket thrust surface.
       

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    6. Install the timing chain dampener to the block.

       Tighten
       Tighten the timing chain dampener bolts to 21 N·m (15 lb ft).

       
       

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    7. Install the timing chain onto the camshaft gear.
       

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    8. Hold the camshaft sprocket with the chain hanging down, and install the chain to the crankshaft gear.
       

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    9. Align the crankshaft timing mark (3) to the timing mark on the bottom of the timing chain dampener (2).
    10. Align the timing mark on the camshaft gear, center line of the locator hole (6), with the timing mark on the top of the chain dampener (5).
    11. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket (1).
        

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    12. Install the camshaft sprocket bolt.
    13. Draw the camshaft sprocket onto the camshaft using the mounting bolt.

        Tighten
        Tighten the camshaft sprocket bolt to 140 N·m (103 lb ft).

    14. Coat the crankshaft and camshaft sprocket with engine oil.
    15. Install the engine front cover. Refer to Engine Front Cover Replacement .

Expert:	Dan
Pos. Feedback:	100.0 %
Accepts:
Answered:	12/17/2008

P&ontiac Technician

GM Certified, GM Mark of Excellence, ASE Master Certified.