GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 ION 🢒 Engine 🢒 Engine Mechanical - 2.0L 🢒 Engine Front Cover Replacement

Removal Procedure
  1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .

    2. Object Number: 1381540 Size: SH
  2. Remove the drive belt tensioner.

    3. Object Number: 1381542 Size: SH
  3. Remove the idler pulley.

    4. Object Number: 412537 Size: SH
  4. Remove the engine front cover to water pump bolt.

    5. Object Number: 412538 Size: SH
  5. Remove the remaining engine front cover bolts.
  6. Remove the engine front cover.
  7. If the engine front cover gasket is damaged, remove the front engine mount. Refer to Engine Mount Replacement .
  8. Remove the front engine mount bracket. Refer to Engine Mount Bracket Replacement .

Installation Procedure

    Object Number: 412538 Size: SH
  1. If removed install a new engine front cover gasket.
  2. Install the front engine mount bracket. Refer to Engine Mount Bracket Replacement .
  3. Install the front engine mount. Refer to Engine Mount Replacement .
  4. Install the engine front cover.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the engine front cover bolts.

    6. Tighten
    Tighten the engine front cover bolts to 25 N·m (18 lb ft).


    Object Number: 412537 Size: SH
  6. Install the water pump bolt.

    7. Tighten
    Tighten the water pump bolt to 25 N·m (18 lb ft).


    Object Number: 1381542 Size: SH
  7. Install the idler pulley.

    8. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 1381540 Size: SH
  8. Install the drive belt tensioner.
  9. Install the drive belt tensioner bolts.

    10. Tighten
    Tighten the drive belt tensioner bolts to 45 N·m (33 lb ft).

  10. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .