Front Cover Replace

Figure 2 Front Cover Assembly:

REMOVAL
1. Disconnect negative battery cable then drain coolant.
2. Drain and recover the cooling system then remove coolant reservoir.
3. Remove tensioner. Drive belt tensioner.
4. Remove generator.
5. Remove power steering pump and support aside.
6. Raise vehicle and suitably support.
7. Remove inner splash shield.
8. Remove flywheel cover at transaxle.
9. Remove starter.
10. Remove crankshaft balancer.
11. Remove serpentine belt idler pulley.
12. Remove oil pan.
13. Remove lower cover bolts then lower vehicle.
14. Remove radiator hose at coolant pump.
15. Remove bypass pipe at front cover.
16. Remove plug wire shield at coolant pump.
17. Remove EVAP canister purge hose.
18. Remove upper front cover bolts then front cover.

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

INSTALLATION
1. Install new front cover gasket.

CAUTION Make sure not to damage sealing surfaces.

2. Apply sealer GM P/N 1052917 (or equivalent) to sealing surfaces of front cover.
3. Install new seal.
4. Install front cover on the engine and install upper cover bolts and torque # 5 bolts to 27-48 Nm (20-35 lb. ft.). and # 4 bolts to 18-36 Nm (13-26 lb. ft.). Refer to figure 2
5. Raise vehicle.
6. Install oil pan.
^ Tighten Oil Pan Bolt to 10 Nm (89 lb. in.)
^ Tighten Oil Pan Nut to 10 Nm (89 lb. in.)
^ Tighten Oil Pan Rear Bolts (2) to 25 Nm (18 lb. ft.)
^ Tighten Oil Pan Stud to Cylinder Block to 6 Nm (63 lb. in.)
7. Install lower cover bolts and torque # 5 bolts to 27-48 Nm (20-35 lb. ft.). and # 4 bolts to 18-36 Nm (13-26 lb. ft.). Refer to figure 2
8. Install serpentine belt idler pulley.
9. Install crankshaft balancer and torque retaining bolt to 103 Nm (76 lb. ft.).
10. Install starter and torque mounting bolts to 43 Nm ( 32 ft. lb. )
11. Install flywheel cover on transaxle.
12. Install inner splash shield.
13. Lower vehicle install radiator hose at coolant pump.
14. Install bypass pipe at front cover.
15. Install EVAP canister purge hose.
16. Install plug wire shield at coolant pump.
17. Install coolant pump pulley and torque mounting bolts to 21 Nm ( 15 ft. lb. )
18. Install power steering pump and torque pump to bracket bolts to 30 Nm ( 22 ft. lb. ).
19. Install generator.
^ Torque generator brace bolt ( to generator ) and generator upper attaching bolt to 25 Nm ( 18 ft. lb. )
^ Torque generator brace bolt ( to engine ) and generator lower attaching bolt to 47 Nm ( 35 ft. lb. )
20. Install tensioner and torque bolt to 54 Nm (40 lb. ft.).
21. Install engine coolant.
22. Connect negative battery cable and tighten bolt to 15 Nm (11 lb. ft.).
23. Inspect for proper fluid levels, leaks, and completion of repair.