Tools Required

1. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Disconnect the intake air temperature (IAT) sensor electrical connector.



4. Remove the air intake duct.
5. Loosen the coolant pump pulley bolts.
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
7. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
10. Disconnect the oil pressure electrical connector.



11. Disconnect the crankshaft position sensor electrical connector.
12. Remove the crankshaft position sensor shield.



13. Remove the crankshaft position sensor studs.
14. Remove the crankshaft position sensor.
15. Remove the oil pan to front cover bolts.
16. Loosen the oil pan bolts, to drop the oil pan slightly in order to add clearance for the front cover installation.
17. Lower the vehicle.



18. Remove the coolant pump pulley bolts.
19. Remove the coolant pump pulley.



20. Remove the radiator outlet hose from the front cover.



21. Remove the crankshaft front oil seal. Use a screwdriver to pry out the crankshaft front oil seal. Use care in order to avoid damage to the seal bore or seal contact surfaces.



22. Remove the engine front cover studs and bolts (1).
23. Remove the engine front cover (2).



24. Remove the engine front cover gasket from the engine block.



25. If replacing the front cover remove the following:

•	Remove the coolant pump bolts (1).

•	Remove the coolant pump (2).

•	Remove the coolant pump gasket (3) from the front cover (4).

•	Remove the oil filter adapter. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .

•	Remove the camshaft position sensor. Refer to Camshaft Position Sensor Replacement in Engine Controls-3.8L.

•	Remove the oil pump gear set. Refer to Oil Pump Cover and Gear Set Replacement .

26. Clean the engine front cover and engine block surfaces.

1. If the front cover was replaced, Install the following parts:

•	Install the oil pump gear set. Refer to Oil Pump Cover and Gear Set Replacement .

•	Install the camshaft position sensor. Refer to Camshaft Position Sensor Replacement in Engine Controls-3.8L.

•	Install the oil filter adapter. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .

2. Install the coolant pump gasket (3) to the front cover (4).
3. Install the coolant pump (2).

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 coolant pump bolts (1).

Tighten
Tighten the coolant pump bolts (1) to 15 N·m (11 lb ft). Use the J 36660-A to torque the coolant pump bolts (1) an additional 80 degrees.




5. Install a new engine front cover gasket to the engine block.



6. Install the engine front cover (2).



7. Apply sealant GM P/N 12346004, Canada P/N 10953480, or equivalent to the engine front cover bolts (1) and stud (2).
8. Install the engine front cover bolts (1) and stud (2).

Tighten
Tighten the front cover bolts (1) and stud (2) to 20 N·m (15 lb ft). Use the J 36660-A to torque the front cover bolts (1) and stud (2) an additional 40 degrees.

9. Install the front crankshaft front oil seal using J 35354 .



10. Install the radiator outlet hose to the front cover.



11. Install the coolant pump pulley.
12. Install the coolant pump pulley bolts.

Tighten
Tighten the coolant pump pulley bolts to 13 N·m (116 lb in).

13. Raise the vehicle.
14. Install the oil pan to front cover bolts.

Tighten
Tighten the oil pan bolts to 14 N·m (124 lb in).




15. Install the crankshaft position sensor.
16. Apply threadlock GM P/N 12345382, Canada P/N 10953489, or equivalent to the crankshaft position sensor studs.
17. Install the crankshaft position sensor studs.

Tighten
Tighten the crankshaft position sensor studs to 30 N·m (22 lb ft).




18. Install the crankshaft position sensor shield.
19. Connect the crankshaft position sensor electrical connector.
20. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
21. Connect the oil pressure sensor electrical connector.
22. Lower the vehicle.
23. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
24. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .



25. Install the air intake duct.



26. Connect the intake air temperature (IAT) sensor electrical connector.
27. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
28. Refill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.