GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Epica 🢒 Engine 🢒 Engine Mechanical - 2.0L and 2.5L 🢒 Lower Crankcase Replacement

Removal Procedure

    Object Number: 1375807 Size: SH
  1. Remove the fuel pump fuse.
  2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.

    3. Warning: Refer to Battery Disconnect Warning in the Preface section.

  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. Refer to Cooling System Draining and Filling.
  5. Drain the engine oil.
  6. Drain the transaxle oil.

    7. Object Number: 1375997 Size: SH
  7. Drain the power steering oil.
  8. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  9. Remove the engine assembly. Refer to Engine Replacement.
  10. Remove the timing chain cover. Refer to Camshaft Timing Chain and Sprocket Replacement.
  11. Remove the compressor.

    12. Object Number: 1376001 Size: SH
  12. Remove the idler retaining bolt, upper pad-to-lower pad bracket bolt, and the idler.

    13. Object Number: 1376006 Size: SH
  13. Remove the lower pad bracket.

    14. Object Number: 1376007 Size: SH
  14. Remove the engine oil dipstick tube.
  15. Remove the crankshaft position (CKP) sensor. Refer to Crankshaft Position Sensor Replacement.

    16. Object Number: 1376011 Size: SH
  16. Remove the bed plate baffle.

    17. Object Number: 1376013 Size: SH
  17. Remove the oil pump chain lever.

    18. Object Number: 1376017 Size: SH
  18. Remove the bed plate outer bolts in the sequence shown.

    19. Object Number: 1376021 Size: SH
  19. Remove the bed plate inner bolts.

Installation Procedure

    Object Number: 1376024 Size: SH
  1. Clean the contact surfaces between the bed plate and the cylinder block.
  2. Apply the liquid gasket, Loctite® 5900-M8585, on the bed plate.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the bed plate and tighten the inner bolts to 33 N·m (24 lb ft). After tightening all the inner bolts, turn the bolts by 135 degrees each.

    4. Object Number: 1376026 Size: SH
  4. Tighten the bed plate outer bolts to 20-26 N·m (15-19 lb ft).

    5. Object Number: 1376028 Size: SH
  5. Install the oil pump. Refer to Oil Pump Replacement.
  6. Install the oil pump chain lever and tighten the bolt to 8 N·m (71 lb in).

    7. Object Number: 1376031 Size: SH
  7. Install the bed plate baffle and tighten the bolts to 8 N·m (71 lb in).
  8. Install the oil pan. Refer to Oil Pan Replacement.

    9. Object Number: 1376034 Size: SH
  9. Install the engine oil dipstick tube.
    10. • Tighten the engine oil dipstick tube bracket bolt to 20 N·m (15 lb ft).
    • Tighten the engine oil dipstick tube bolt to 9 N·m (80 lb in).
  10. Install the CKP sensor. Refer to Crankshaft Position Sensor Replacement.

    11. Object Number: 1376037 Size: SH
  11. Install the lower pad bracket and tighten the bolts to 40 N·m (30 lb ft).

    12. Object Number: 1376039 Size: SH
  12. Install the idler.
    13. • Tighten the idler retaining bolts to 45 N·m (33 lb ft).
    • Tighten the upper pad-to-lower pad bracket bolt to 35 N·m (26 lb ft).

    Object Number: 1376043 Size: SH
  13. Install the compressor and tighten the retaining bolts and nuts to 25 N·m (18 lb ft).

    14. Object Number: 1375919 Size: SH
  14. Install the timing chain and timing chain cover. Refer to Camshaft Timing Chain and Sprocket Replacement.
  15. Install the engine assembly. Refer to Engine Replacement.
  16. Install the fuel pump fuse.
  17. Connect the negative battery cable.
  18. Refill the crankcase with engine oil.
  19. Refill the engine coolant system. Refer to Cooling System Draining and Filling.
  20. Fill and bleed the power steering system. Refer to Power Steering System Bleeding.
  21. Refill the A/C System. Refer to Refrigerant Recovery and Recharging.