Tools Required

J 37228 Seal Cutter

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 negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
5. Remove the right fender wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
6. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement in Engine Cooling.
7. Remove the oil fill tube. Refer to Oil Filler Tube Replacement .
8. Remove the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement .
9. Remove the water pump. Refer to Water Pump Replacement in Engine Cooling.



10. Disconnect the camshaft position (CMP) sensor electrical connector.
11. Remove the CMP sensor bolt and sensor.



12. Disconnect the crankshaft position (CKP) sensor electrical connector.
13. Remove the CKP sensor bolt and sensor.
14. Remove the CKP sensor spacer bolts and spacer.
15. Remove and discard the O-rings from the CKP sensor and spacer.



16. Remove the upper oil pan to engine front cover bolts.



17. Remove the turbocharger coolant feed pipe bracket bolts and bracket.



18. Remove the engine front cover bolts.
19. Separate the engine front cover from the cylinder block and upper oil pan using J 37228 .

Important: Do not bend the turbocharger coolant pipe.

20. Remove the engine front cover.



21. If necessary, remove the pressure relief valve O-ring.
22. Clean and inspect the front cover. Refer to Engine Front Cover Cleaning and Inspection .

1. If necessary, install a NEW pressure relief valve O-ring.

Tighten
Tighten the valve to 39 N·m (29 lb ft).




2. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high, bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the engine front cover sealing surface to the engine block.
3. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high, bead of sealant GM P/N 97720043 (Canadian P/N 88901148), or equivalent to the engine front cover sealing surface to the upper oil pan.



4. Install the engine front cover.

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.

5. Install the engine front cover bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




6. Install the upper oil pan to engine front cover bolts.

Tighten
Tighten the bolts to 21 N·m (15 lb ft).




7. Install the turbocharger coolant feed pipe bracket and bolts.

Tighten
Tighten the bolts to 21 N·m (15 lb ft).




8. Install the CMP sensor bolt and sensor.

Tighten
Tighten the bolt to 10 N·m (89 lb in).

9. Connect the CMP sensor electrical connector.



10. Install a NEW O-ring seal to the CKP sensor spacer.
11. Lubricate the O-ring seal with clean engine oil.

Important: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "B" spacer.

12. Install the CKP sensor spacer.
13. Install the CKP sensor spacer bolts.

Tighten
Tighten the bolts to 10 N·m (89 ft in).

14. Install a NEW O-ring seal to the CKP sensor.
15. Lubricate the O-ring seal with clean engine oil.
16. Install the CKP sensor.
17. Install the CKP sensor bolt.

Tighten
Tighten the bolt to 10 N·m (89 lb in).

18. Install the water pump. Refer to Water Pump Replacement in Engine Cooling.
19. Install the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement .
20. Install the oil fill tube. Refer to Oil Filler Tube Replacement .
21. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement in Engine Cooling.
22. Install the right fender wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



24. Install the upper intake manifold cover.
25. Install the upper intake manifold cover to the outlet duct.
26. Tighten the outlet duct clamp at the upper intake manifold cover.

Tighten
Tighten the clamp to 6 N·m (53 lb in).