GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Lumina 🢒 Engine 🢒 Engine Mechanical - 3.1L and 3.4L 🢒 Engine Front Cover Replacement

Removal Procedure
  1. Drain the engine coolant.
  2. Remove the drive belt. Refer to Drive Belt Replacement .
  3. Remove the hood panel.

    4. Object Number: 54655 Size: SH
  4. Remove the engine mount strut and air conditioning compressor bracket.
  5. Remove the engine mount strut bracket.
  6. Remove the electric engine coolant fan.
  7. Install the engine support fixture.
  8. Raise the vehicle. Support the vehicle suitably.
  9. Remove the left exhaust manifold pipe. Refer to Exhaust Manifold Replacement .
  10. Remove the intermediate steering shaft bolt. Move the cover aside.
  11. Drain the engine oil.
  12. Remove the engine splash shield.
  13. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  14. Support the drivetrain and the front suspension frame with floor stands.
  15. Remove the transaxle mount frame side bracket nuts from the drivetrain and suspension frame.
  16. Remove the engine mount frame side nuts from the drivetrain and front suspension frame. Refer to Engine Mount Replacement .

    17. Object Number: 54400 Size: SH
  17. Remove the lower drivetrain and front suspension frame bolts.
  18. Lower the drivetrain and front suspension frame.
  19. Remove the engine mount. Refer to Engine Mount Replacement .
  20. Remove the flywheel inspection cover.
  21. Remove the starter motor.
  22. Remove the transaxle mount from the oil pan. Refer to Engine Mount Replacement .
  23. Remove the oil pan. Refer to Oil Pan Replacement .
  24. Raise the drivetrain and front suspension frame.
  25. Install the rear drivetrain and front suspension frame bolts.
  26. Lower the vehicle.
  27. Remove the coolant recovery reservoir.
  28. Remove the serpentine drive belt shield.
  29. Remove the power steering pump pulley. Refer to SECTION 3B.
  30. Remove the power steering pump bolts. Move the power steering pump aside. Refer to SECTION 3B.

    31. Object Number: 54419 Size: SH
  31. Remove the thermostat bypass pipe clip nut from the upper intake manifold.
  32. Remove the thermostat bypass pipe from the coolant pump.

    33. Object Number: 54296 Size: SH
  33. Remove the coolant pump pulley.
  34. Remove the lower radiator outlet hose from the coolant pump.
  35. Remove the serpentine drive belt tensioner. Refer to Drive Belt Tensioner Replacement .

    36. Object Number: 54378 Size: SH
  36. Remove the crankshaft position sensor from the front cover.
  37. Remove the crankshaft position sensor.

    38. Object Number: 54375 Size: SH
  38. Remove the front cover bolts.
  39. Remove the front cover.
  40. Remove the front cover gasket.

    41. Object Number: 54303 Size: SH
  41. Remove the coolant pump from the front cover.
  42. Clean the engine front cover and engine block gasket surfaces.
  43. Inspect the engine front cover for damage to the seals or the gasket surface.

Installation Procedure

    Object Number: 54303 Size: SH
  1. Install the coolant pump to the front cover.

    2. Important: Coat both sides of the lower tabs of the engine front cover gasket with GM P/N 1052080 or equivalent.

  2. Install the engine front cover gasket.

    3. Object Number: 54375 Size: SH
  3. Install the engine front cover.
  4. Install the engine front cover bolts.

    5. Tighten

        • Tighten the large bolts (2) to 47 N·m (35 lb ft).
        • Tighten the small bolts (1) to 21 N·m (15 lb ft).

    Object Number: 54378 Size: SH
  5. Install the crankshaft position sensor to the front cover.
  6. Install the accessory drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  7. Install the lower radiator outlet hose to the coolant pump.

    8. Object Number: 54296 Size: SH
  8. Install the coolant pump pulley.

    9. Object Number: 54419 Size: SH
  9. Install the thermostat bypass pipe to the coolant pump.
  10. Install the thermostat bypass pipe clip nut to the upper intake manifold.
  11. Position the power steering pump. Install the power steering pump bolts. Refer to SECTION 3B.
  12. Install the serpentine drive belt shield.
  13. Install the coolant recovery reservoir. Refer to SECTION 6B.
  14. Raise the vehicle. Support the vehicle suitably.
  15. Support the drivetrain and the front suspension frame with floor stands.

    16. Object Number: 54400 Size: SH
  16. Remove the rear drivetrain and front suspension frame bolts.
  17. Lower the drivetrain and front suspension frame.
  18. Install the oil pan. Refer to Oil Pan Replacement .
  19. Install the transaxle mount to the oil pan. Refer to SECTION 7A.
  20. Install the starter motor. Refer to SECTION 6D2.
  21. Install the flywheel inspection cover.
  22. Install the engine mount. Refer to Engine Mount Replacement .
  23. Raise the drivetrain and front suspension frame.
  24. Install the rear drivetrain and front suspension frame bolts.
  25. Install the engine mount frame side nuts to the drivetrain and front suspension frame. Refer to Engine Mount Replacement .
  26. Remove the floor stands from the drivetrain and the front suspension frame with floor stands.
  27. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  28. Install the engine splash shield.
  29. Install the intermediate steering shaft cover. Install the intermediate steering shaft bolt.
  30. Install the front exhaust manifold pipe. Refer to SECTION 6F.
  31. Lower the vehicle.
  32. Remove the engine support fixture.
  33. Install the electric engine coolant fan. Refer to SECTION 6B.

    34. Object Number: 54655 Size: SH
  34. Install the engine mount strut and air conditioning compressor bracket.
  35. Install the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
  36. Install the hood panel.
  37. Install the accessory drive belt. Refer to Drive Belt Replacement .
  38. Add engine oil.
  39. Refill the engine coolant. Add two engine coolant sealant pellets. Use GM P/N 3634621.
  40. Bleed the engine coolant system through the air bleed vents. Refer to SECTION 6B.