Front Cover Replace

Figure 2 Front Cover Assembly:

REMOVAL
1. Remove air cleaner.
2. Disconnect negative battery cable then drain coolant.
3. Remove tensioner. Drive belt tensioner.
4. Remove generator.
5. Remove power steering and support aside.
6. Remove radiator hose clamp at coolant pump.
7. Remove radiator hose at coolant pump.
8. Remove heater coolant hoses at thermostat bypass pipe.
9. Remove thermostat bypass pipe from front cover.
10. Remove crankshaft balancer.
11. Remove starter.
12. Remove oil pan.
13. Lower vehicle.
14. Remove front cover bolts, cover, and gasket.

CLEAN
^ Mating surfaces of the front cover and cylinder block.
^ Sealing surfaces with degreaser.

INSTALLATION
1. Apply sealer GM P/N 1052080 (or equivalent) to both sides of the lower edges of the front cover gasket where the gasket contacts the oil pan gasket.
2. Install new front cover gasket.

CAUTION Make sure not to damage sealing surfaces.

3. Install new seal.
4. Install front cover and front cover bolts. Refer to figure 2
^ Tighten Large bolts ( # 5 ) to 27-48 Nm (20-35 lb. ft.).
^ Tighten Small bolts ( # 4 ) to 18-36 Nm (13-26 lb. ft.).
5. Raise vehicle.
6. Install oil pan.
^ Tighten oil pan bolts (Rear) 25 Nm (18 lb. ft.)
^ Tighten oil pan bolts (Remaining) 10 Nm (89 lb. in.)
^ Tighten oil pan nut 10 Nm (89 lb. in.)
7. Install starter and torque bolts to 43 Nm ( 32 ft. lb. ).
8. Install crankshaft balancer and torque retaining bolt to 103 Nm (76 lb. ft.).
9. Install thermostat bypass pipe to front cover.
10. Install heater coolant hoses at thermostat bypass pipe.
11. Install radiator hose and hose clamp at coolant pump.
12. Install power steering pump and torque bolts to 34 Nm (25 lb. ft.).
13. Install generator.
^ Tighten bracket (front) to generator bolt to 25 Nm (18 lb. ft.).
^ Tighten brace (rear) to generator stud to 25 Nm (18 lb. ft.).
^ Tighten brace (rear) to engine to 50 Nm (37 lb. ft.).

14. Install tensioner and torque tensioner bolt to 54 Nm (40 lb. ft.).
15. Install engine coolant.
16. Connect negative battery cable and torque bolt to 15 Nm (11 ft.lb.).
17. Install air cleaner.
18. Inspect for proper fluid levels, leaks, and completion of repair.