Tools Required
J 36660-A Torque Angle
Meter
Removal Procedure
- Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Drain the engine oil. Refer to
Engine Oil and Oil Filter Replacement
.
- Drain the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Lower the vehicle.
- Loosen the water pump pulley bolts.
- Remove the drive belt tensioner. Refer to
Drive Belt Tensioner Replacement
.
- Remove the water pump pulley.
- Remove the crankshaft balancer. Refer to
Crankshaft Balancer Replacement
.
Important: Be careful not to damage the crankshaft.
- Pry out the crankshaft front oil seal with a suitable tool such as a
large screwdriver. Use care to avoid damaging the crankshaft front oil
seal bore or the crankshaft front oil seal contact surfaces.
- Disconnect the electrical connectors from the following:
• | Camshaft position (CMP) sensor. |
• | Crankshaft position (CKP) sensor. |
- Remove the crankshaft
position sensor shield.
- Lower the vehicle.
- Remove the radiator outlet hose from the water pump. Refer to
Radiator Outlet Hose Replacement
.
- Install the engine support fixture. Refer to
Engine Support Fixture
.
- Remove the engine mount bracket for oil pan access. Refer to
Engine Mount and Bracket Replacement
.
Important: The oil pan can be dropped slightly for engine front cover clearance
if all pan bolts are loosened and the oil level sensor is removed.
- Disconnect the oil level sensor electrical connector.
- Remove the oil level sensor.
- Remove the oil pan-to-engine front cover bolts.
Important: DO NOT remove the remaining oil pan bolts.
- Loosen the remaining oil pan bolts to gain access for the engine front
cover removal.
- Remove the oil filter.
- Remove the crankshaft
position sensor.
- Remove the engine front
cover bolts.
- Remove the engine front cover with the oil filter adapter as one
assembly.
- Remove the engine front
cover gasket.
- If replacing the engine
front cover, remove the oil filter adapter and pressure relief valve from
the engine front cover.
- If replacing the engine
front cover, remove the water pump from the engine front cover. Refer to
Water Pump Replacement
in Engine Cooling.
- If replacing the engine
front cover, remove the oil pump cover and gear set from the engine front
cover. Refer to
Oil Pump Cover and Gear Set Replacement
.
- Inspect the oil pump cover and gear set. Refer to
Oil Pump Cleaning and Inspection
in Engine Mechanical - 3.8L
Unit Repair.
- If replacing the engine front cover, remove the camshaft position sensor
from the engine front cover.
- Inspect the timing chain for overall in and out movement. Maximum
movement is 25.4 mm (1 in). Refer to
Camshaft Timing Chain and Sprocket Cleaning and Inspection
in Engine Mechanical - 3.8L
Unit Repair.
- Inspect the sprockets for wear.
- Inspect the oil pan gasket. Replace the oil pan gasket if necessary.
- Clean the engine front cover mating surfaces.
Installation Procedure
- If replacing the engine front cover, install the camshaft position sensor.
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.
- Install the camshaft position sensor bolt.
Tighten
Tighten the bolt to 10 N·m (89 lb in).
- If replacing the engine
front cover, install the oil pump cover and gear set to the engine front
cover. Refer to
Oil Pump Cover and Gear Set Replacement
.
- If replacing the engine
front cover, install the water pump to the engine front cover.
- Install the long water pump bolts to the water pump.
Tighten
Tighten the long water pump bolts to 20 N·m (15 lb ft).
- Install the short water pump bolts to the water pump.
Tighten
Tighten the short water pump bolts to 15 N·m (11 lb ft).
- If replacing the engine
front cover, install the oil filter adapter and pressure relief valve to
the engine front cover.
- Install the oil filter adapter bolts.
Tighten
Tighten the bolts to 30 N·m (22 lb ft).
- Install the new engine
front cover gasket. Ensure that the sealing surfaces are not damaged.
- Apply sealer GM P/N 12346004, (Canadian P/N 10953480)
or equivalent to the bolt threads.
- Align the cogs on the crankshaft sprocket with the cogs on the
oil pump gear set in the engine front cover.
- Install the engine front
cover to the engine.
- Install the engine front cover bolts (1-7).
Tighten
- Tighten the bolts to 20 N·m (15 lb ft).
- Use the J 36660-A
to rotate the bolts an additional 40 degrees.
- Install the crankshaft
position sensor.
- Install the crankshaft position sensor studs.
Tighten
Tighten the studs to 30 N·m (22 lb ft).
- Install the new crankshaft front oil seal. Refer to
Crankshaft Front Oil Seal Replacement
.
- Install the oil pan-to-engine front cover bolts.
Tighten
Tighten the oil pan bolts to 14 N·m (125 lb in).
- Install the oil level
sensor.
Tighten
Tighten the sensor to 20 N·m (15 lb ft).
- Connect the oil level sensor electrical connector.
- Install the engine mount bracket. Refer to
Engine Mount and Bracket Replacement
.
- Install the water pump pulley and the bolts.
Tighten
Tighten the bolts to 13 N·m (116 lb in).
- Install the oil filter
and the oil pan drain plug. Refer to
Engine Oil and Oil Filter Replacement
.
- Install the crankshaft
position sensor shield.
- Connect the electrical connectors to the following:
• | Crankshaft position (CKP) sensor. |
• | Camshaft position (CMP) sensor. |
- Install the crankshaft balancer. Refer to
Crankshaft Balancer Replacement
.
- Lower the vehicle.
- Install the radiator outlet hose. Refer to
Radiator Outlet Hose Replacement
in Engine Cooling.
- Remove the engine support fixture.
- Install the drive belt tensioner. Refer to
Drive Belt Tensioner Replacement
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Fill the crankcase with engine oil. Refer to
Engine Oil and Oil Filter Replacement
.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
- Inspect for leaks.
- Perform the CKP system variation learn procedure. Refer to
Crankshaft Position System Variation Learn
in Engine
Controls - 3.8L.