Timing Cover: Service and Repair

Engine Front Cover Replacement

- Tools Required
- J 37228 Seal Cutter

Removal Procedure





1. Loosen the outlet duct clamp at the upper intake manifold cover.
2. Remove the upper intake manifold cover from the outlet duct.
3. Remove the upper intake manifold cover.
4. Disconnect the battery negative cable.
5. Drain the engine coolant and the engine block.
6. Remove the right front fender wheelhouse panel.
7. Remove the upper fan shroud.
8. Remove the fan clutch.
9. Remove the drive belt.
10. Remove the oil fill tube.
11. Remove the thermostat housing crossover.
12. Remove the crankshaft balancer.
13. Remove the crankshaft front oil seal.
14. Remove the water pump.





15. Disconnect the camshaft sensor electrical connector.
16. Remove the camshaft sensor bolt and sensor.





17. Disconnect the crankshaft sensor connector.
18. Remove the crankshaft sensor bolt and sensor.
19. Remove the crankshaft position sensor spacer bolts.
20. Remove the crankshaft position sensor spacer.





21. Remove the 5 bolts retaining the upper oil pan to the engine front cover.





22. Remove the bracket bolts and the bracket for the turbocharger outlet coolant pipe.





23. Remove the 13 bolts for the engine front cover.
24. Using the J 37228 separate the engine front cover from the cylinder block and the upper oil pan.

Important: Do not bend the turbocharger coolant pipe.

25. Remove the engine front cover.
26. Remove the O-ring from the engine front cover.





27. Remove the oil pressure relief valve from the engine front cover.
28. Clean the engine front cover with a suitable cleaning solvent.
29. Clean the engine front cover and the engine mating surfaces.
30. Inspect the engine front cover mating surfaces for damage.
31. Inspect the engine front cover O-ring sealing surfaces for damage.
32. Replace the engine front cover if any damage is found.

Installation Procedure





Notice: Refer to Fastener Notice in Service Precautions.

1. Install the oil pressure relief valve with a new O-ring seal in the engine front cover.
- Tighten the valve to 41 Nm (30 ft. lbs.).





2. Apply a 2 - 3 mm (1/8 inch) wide to 0.5 - 1.5 mm (1/16 inch) high bead of sealant GM PIN United States 97720043, GM P/N Canada 88900148, or equivalent to the engine front cover sealing surface to the engine block.
3. Apply a 2 - 3 mm (1/8 inch) wide to 0.5 - 1.5 mm (1/16 inch) high bead of sealant GM P/N United States 97720043, GM P/N Canada 88900148, or equivalent to the engine front cover sealing surface to the upper oil pan.





4. Install the new O-ring (1) in the front cover. Lubricate the O-ring with clean engine oil.





5. Install the engine front cover.
6. Install the engine front cover 13 bolts.
- Tighten the bolts to 21 Nm (15 ft. lbs.).





7. Install the 5 bolts retaining the upper oil pan to the engine front cover.
- Tighten the bolts to 21 Nm (15 ft. lbs.).





8. Install the turbocharger coolant outlet pipe bracket and bolts.
- Tighten the turbocharger coolant outlet pipe bracket bolts to 21 Nm (15 ft. lbs.).





9. Install the camshaft sensor bolt and sensor.
- Tighten the bolt to 9 Nm (80 inch lbs.).
10. Connect the camshaft sensor electrical connector.





Important: The crankshaft position sensor spacers are machined with different timing positions. If the spacer requires replacement, replace with the same part number.

11. Install the crankshaft position sensor spacer.
12. Install the crankshaft position sensor spacer bolts.
- Tighten the bolts to 10 Nm (89 ft inch). ?????
13. Install the crankshaft position Benson
14. Install the crankshaft position sensor bolt.
- Tighten the bolt to 10 Nm (89 inch lbs.).
15. Install the water pump.
16. Install the crankshaft front oil seal.
17. Install the crankshaft balancer.
18. Install the thermostat housing crossover.
19. Install the oil fill tube.
20. Install the drive belt.
21. Install the upper fan shroud.
22. Install the right front fender wheelhouse panel.
23. Fill the engine coolant.
24. Connect the battery negative cable.





25. Install the upper intake manifold cover.
26. Install the upper intake manifold cover to the outlet duct.
27. Tighten the outlet duct clamp at the upper intake manifold cover.
- Tighten the clamp to 6 Nm (53 inch lbs.).