GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  4. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  6. Remove the oil pan. Refer to Oil Pan Replacement .
  7. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  8. Remove the power steering pump with the lines and reposition the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  9. Remove the thermostat bypass pipe from the engine front cover. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  10. Remove the radiator outlet hose from the engine front cover. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  11. Remove the water pump from the engine front cover. Refer to Water Pump Replacement in Engine Cooling.

  12. Object Number: 190536  Size: SH
  13. Remove the crankshaft position (CKP) sensor wiring harness bracket bolt.
  14. Remove the CKP sensor wiring harness bracket.

  15. Object Number: 95865  Size: SH
  16. Remove the engine front cover bolts (1,2 and 3).
  17. Remove the engine front cover.

  18. Object Number: 61818  Size: SH
  19. Remove the engine front cover gasket.
  20. Clean and inspect the engine front cover. Refer to Engine Front Cover Cleaning and Inspection .
  21. If replacing the engine front cover, remove the drive belt shield bolt and the drive belt shield.
  22. If replacing the engine front cover remove the water pump. Refer to Water Pump Replacement in Engine Cooling.

  23. Object Number: 190537  Size: SH
  24. If replacing the engine front cover, remove the 24X CKP sensor. Refer to Crankshaft Position Sensor Replacement in Engine Controls - 3.4L.

Installation Procedure


    Object Number: 190537  Size: SH
  1. If removed, install the 24X CKP sensor. Refer to Crankshaft Position Sensor Replacement in Engine Controls - 3.4L.
  2. If removed install the water pump. Refer to Water Pump Replacement in Engine Cooling.
  3. 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. If removed, install the drive belt shield.
  5. Install the drive belt shield bolt.

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


    Object Number: 61819  Size: SH
  6. Apply sealant to both sides of the engine front cover gasket with GM P/N 12346004 (Canadian P/N 10953480) or equivalent.

  7. Object Number: 61818  Size: SH
  8. Install the engine front cover gasket.

  9. Object Number: 95865  Size: SH
  10. Install the engine front cover.
  11. Install the engine front cover bolts (1,2 and 3).
  12. Tighten

        • Tighten the small engine front cover bolts (1) to 27 N·m (20 lb ft).
        • Tighten the large engine front cover bolts (2,3) to 55 N·m (41 lb ft).

    Object Number: 190536  Size: SH
  13. Install the CKP sensor wiring harness bracket.
  14. Install the crankshaft position (CKP) sensor wiring harness bracket bolt.
  15. Tighten
    Tighten the bolt to 27 N·m (20 lb ft).

  16. Install the radiator outlet hose to the engine front cover. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  17. Install the thermostat bypass pipe to the engine front cover. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  18. Install the power steering pump with the lines. Refer to Power Steering Pump Replacement in Power Steering System.
  19. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  20. Install the oil pan. Refer to Oil Pan Replacement .
  21. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  22. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  23. Fill the crankcase with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
  24. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  26. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.4L.