GM Service Manual Online
For 1990-2009 cars only

Tools Required

J 37228 Seal Cutter

Removal Procedure


    Object Number: 813243  Size: SH
  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. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  5. Drain the engine coolant and the engine block. Refer to Cooling System Draining and Filling in Engine Cooling.
  6. Remove the right front fender wheelhouse panel.
  7. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement in Engine Cooling.
  8. Remove the fan clutch. Refer to Fan Clutch Replacement in Engine Cooling.
  9. Remove the drive belt. Refer to Drive Belt Replacement .
  10. Remove the oil fill tube. Refer to Oil Filler Tube Replacement .
  11. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
  12. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  13. Remove the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement .
  14. Remove the water pump. Refer to Water Pump Replacement in Engine Cooling.

  15. Object Number: 660340  Size: SH
  16. Disconnect the camshaft sensor electrical connector.
  17. Remove the camshaft sensor bolt and sensor.

  18. Object Number: 663804  Size: SH
  19. Disconnect the crankshaft sensor connector.
  20. Remove the crankshaft sensor bolt and sensor.
  21. Remove the crankshaft position sensor spacer bolts.
  22. Remove the crankshaft position sensor spacer.

  23. Object Number: 738866  Size: SH
  24. Remove the 5 bolts retaining the upper oil pan to the engine front cover.

  25. Object Number: 699335  Size: SH
  26. Remove the bracket bolts and the bracket for the turbocharger outlet coolant pipe.

  27. Object Number: 738865  Size: SH
  28. Remove the 13 bolts for the engine front cover.
  29. Using the J 37228 separate the engine front cover from the cylinder block and the upper oil pan.
  30. Important: Do not bend the turbocharger coolant pipe.

  31. Remove the engine front cover.
  32. Remove the O-ring from the engine front cover.

  33. Object Number: 738862  Size: SH
  34. Remove the oil pressure relief valve from the engine front cover.
  35. Clean the engine front cover with a suitable cleaning solvent.
  36. Clean the engine front cover and the engine mating surfaces.
  37. Inspect the engine front cover mating surfaces for damage.
  38. Inspect the engine front cover O-ring sealing surfaces for damage.
  39. Replace the engine front cover if any damage is found.

Installation Procedure


    Object Number: 738862  Size: SH

    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.

  1. Install the oil pressure relief valve with a new O-ring seal in the engine front cover.
  2. Tighten
    Tighten the valve to 41 N·m (30 lb ft).


    Object Number: 663817  Size: SH
  3. Apply a 2-3 mm (1/8 in) wide to 0.5-1.5 mm (1/16 in) high bead of sealant GM P/N United States 97720043, GM P/N Canada 88901148, or equivalent to the engine front cover sealing surface to the engine block.
  4. Apply a 2-3 mm (1/8 in) wide to 0.5-1.5 mm (1/16 in) high bead of sealant GM P/N United States 97720043, GM P/N Canada 88901148, or equivalent to the engine front cover sealing surface to the upper oil pan.

  5. Object Number: 663614  Size: SH
  6. Install the new O-ring (1) in the front cover.
  7. Lubricate the O-ring with clean engine oil.


    Object Number: 738865  Size: SH
  8. Install the engine front cover.
  9. Install the engine front cover 13 bolts.
  10. Tighten
    Tighten the bolts to 21 N·m (15 lb ft).


    Object Number: 738866  Size: SH
  11. Install the 5 bolts retaining the upper oil pan to the engine front cover.
  12. Tighten
    Tighten the bolts to 21 N·m (15 lb ft).


    Object Number: 699335  Size: SH
  13. Install the turbocharger coolant outlet pipe bracket and bolts.
  14. Tighten
    Tighten the turbocharger coolant outlet pipe bracket bolts to 21 N·m (15 lb ft).


    Object Number: 660340  Size: SH
  15. Install the camshaft sensor bolt and sensor.
  16. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  17. Connect the camshaft sensor electrical connector.

  18. Object Number: 663804  Size: SH

    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.

  19. Install the crankshaft position sensor spacer.
  20. Install the crankshaft position sensor spacer bolts
  21. Tighten
    Tighten the bolts to 10 N·m (89 ft in).

  22. Install the crankshaft position sensor.
  23. Install the crankshaft position sensor bolt.
  24. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  25. Install the water pump. Refer to Water Pump Replacement in Engine Cooling.
  26. Install the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement .
  27. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  28. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
  29. Install the oil fill tube. Refer to Oil Filler Tube Replacement .
  30. Install the drive belt. Refer to Drive Belt Replacement .
  31. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement in Engine Cooling.
  32. Install the right front fender wheelhouse panel.
  33. Fill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  34. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

  35. Object Number: 813243  Size: SH
  36. Install the upper intake manifold cover.
  37. Install the upper intake manifold cover to the outlet duct.
  38. Tighten the outlet duct clamp at the upper intake manifold cover.
  39. Tighten
    Tighten the clamp to 6 N·m (53 lb in).