GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.1L 🢒 Engine Front Cover Replacement

Removal Procedure
  1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  2. Remove the oil pan. Refer to Oil Pan Replacement .

    3. Object Number: 54378 Size: SH
  3. Remove the crankshaft position (CKP) sensor. Refer to Crankshaft Position Sensor Replacement in Engine Controls - 3.1L.
  4. Remove the lower front cover bolts (1).
  5. Lower the vehicle.

    6. Object Number: 63031 Size: SH
  6. Remove the engine mount . Refer to Engine Mount Replacement .
  7. Remove the engine mount bracket support.
  8. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  9. Loosen water pump pulley bolts.
  10. Remove drive belt. Refer to Drive Belt Replacement .
  11. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  12. Remove water pump pulley bolts and pulley.
  13. Remove the Thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  14. Remove the lower radiator hose to coolant outlet housing.

    15. Object Number: 54375 Size: SH
  15. Remove the upper front cover bolts (2).
  16. Remove the front cover.
  17. Remove the front cover oil seal. Refer to Crankshaft Front Oil Seal Replacement .
  18. Clean the mating surfaces of the following items:
    19. 18.1. The front cover
    18.2. The oil pan
    18.3. The cylinder block
  19. Clean the sealing surfaces using degreaser.

Installation Procedure

    Important: Do not damage the sealing surfaces.

  1. Install the front cover gasket.
  2. Install the front cover oil seal. Refer to Crankshaft Front Oil Seal Replacement .

    3. Object Number: 54375 Size: SH
  3. Place the front cover on the engine.

    4. 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 upper 2 front cover bolts (2).

    5. Tighten
    Tighten the front cover (upper) bolts to 21 N·m (15 lb ft).

  5. Install the lower radiator hose to coolant housing.
  6. Install the thermostat bypass pipe . Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  7. Raise the vehicle.
  8. Install the front cover (lower) bolts (1).

    9. Tighten

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

    Object Number: 54378 Size: SH
  9. Install the CKP sensor. Refer to Crankshaft Position Sensor Replacement in Engine Controls - 3.1L.
  10. Install crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  11. Lower the vehicle.
  12. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  13. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  14. Install water pump pulley and bolts.
  15. Install drive belt. Refer to Drive Belt Replacement .

    16. Object Number: 63031 Size: SH
  16. Install the engine mount. Refer to Engine Mount Replacement .

    17. Tighten
    Tighten water pump pulley bolts to 25 N·m (19 lb ft).

  17. Install oil pan. Refer to Oil Pan Replacement .
  18. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.