GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 RELAY Ext. 🢒 Engine 🢒 Engine Mechanical - 3.5L (LX9) 🢒 Engine Front Cover Replacement

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

    11. Object Number: 95865 Size: SH
  11. Remove the engine front cover bolts.
  12. Remove the engine front cover.

    13. Object Number: 61818 Size: SH
  13. Remove the engine front cover gasket.
  14. Clean and inspect the engine front cover. Refer to Engine Front Cover Cleaning and Inspection .
  15. If replacing the engine front cover, remove the drive belt shield bolt and the drive belt shield.
  16. If replacing the engine front cover remove the water pump. Refer to Water Pump Replacement .

Installation Procedure

    Object Number: 61819 Size: SH
  1. Apply sealant to both sides of the engine front cover gasket with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers for the 3.5L engine.

    2. Apply the sealer no less than 5.0 mm (0.20 in) wide.


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

    3. Object Number: 95865 Size: SH
  3. Install the engine front cover.
  4. Install the engine front cover bolts (1, 2, and 3).

    5. 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).
  5. Install the power steering pump to the engine. Refer to Power Steering Pump Replacement in Power Steering System.
  6. Install the water pump. Refer to Water Pump Replacement .
  7. Install the radiator outlet hose to the engine front cover. Refer to Radiator Outlet Hose Replacement .
  8. Install the thermostat bypass pipe to the engine front cover. Refer to Thermostat Bypass Pipes Replacement .
  9. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  10. Install the oil pan. Refer to Oil Pan Replacement .
  11. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  12. Fill the crankcase with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
  13. Fill the cooling system. Refer to Cooling System Draining and Filling .
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .