Front Cover And Oil Pump Assembly Replacement: Installation

IMPORTANT:  A new oil seal can be installed either in or out of the vehicle. Refer to FRONT COVER OIL SEAL REPLACEMENT - L61 .

1. Install new front cover gasket.
2. Install front cover assembly.
3. Install front cover assembly bolts and lower water pump bolt.

   Torque: 

   Front Cover-to-Block Bolts - L61: 25 N.m (18 ft-lbs) 

   Torque: 

   Water Pump Bolts - L61: 25 N.m (18 ft-lbs) 

4. Lubricate front seal and sealing surface of pulley with clean motor oil.
5. Installer balancer pulley onto crankshaft indexing keyway. Use care to properly align the flats on balancer pulley with flats on oil pump drive in front cover assembly.
6. Install crankshaft damper pulley.
7. Install new crankshaft balancer pulley bolt with washer assembly.
   Fig 1: Installing Crankshaft Damper Pulley

   Courtesy of GENERAL MOTORS CORP.
8. Install J38122 Crankshaft Pulley Holder.

   Torque: 

   Crankshaft Pulley Bolt - L61: 100 N.m (74 ft-lbs)+75° 

   Fig 2: Installing Crankshaft Pulley Holder

   Courtesy of GENERAL MOTORS CORP.
9. Install drive belt tensioner assembly.

   Torque: 

   Drive Belt Tensioner Bolt - L61: 45 N.m (33 ft-lbs) 

   Fig 3: Installing Drive Belt Tensioner Assembly

   Courtesy of GENERAL MOTORS CORP.
10. Route belt around alternator and A/C compressor. Install J39914 Accessory Drive Belt tool onto tensioner and unload spring tension from tensioner while positioning belt.
    Fig 4: Routing Belt Around Alternator And A/C Compressor

    Courtesy of GENERAL MOTORS CORP.
11. Release tensioner and remove tool.
12. Install right engine inner splash shield.
13. Install right wheel and hand tighten wheel nuts.
14. Lower vehicle.
15. Tighten tire nuts.

    Torque: 

    Wheel Nuts: 125 N.m (92 ft-lbs) 

16. Install right hand engine bracket and bolts to engine.

    Torque: 

    Engine Mount Bracket-to-Engine Bolts L61: 110 N.m (81 ft-lbs) 

    Fig 5: Installing Right Hand Engine Bracket And Bolts

    Courtesy of GENERAL MOTORS CORP.
17. Install right hand engine mount over body side rail studs.
18. Install right hand engine mount nuts.

    Torque: 

    Engine Mount Bracket-to-Body Nuts L61: 110 N.m (81 ft-lbs) 

    Fig 6: Installing Right Hand Engine Mount

    Courtesy of GENERAL MOTORS CORP.
19. Install right hand engine mount bolts to engine mount bracket.

    Torque: 

    Engine Mount-to-Engine Mount Bracket Bolts L61: 50 N.m (37 ft-lbs) 

    IMPORTANT:  When starting vehicle, check for excessive idle shake. Powertrain re-balance may be required.

20. Remove SA9105E Engine Three Bar Fixture.
21. Position outlet resonator/duct assembly into position.
    Fig 7: Position Outlet Resonator/Duct Assembly Into Position

    Courtesy of GENERAL MOTORS CORP.
22. Connect PCV fresh air vent hose assembly.
23. Tighten clamp at throttle body assembly.
24. Position outlet resonator/duct assembly up with support bracket and install push-pin.
25. Tighten clamp at air cleaner assembly.
26. Connect intake air temperature (IAT) sensor connector.
27. Connect negative battery cable.

Torque: 

Battery Terminal Bolt: 17 N.m (13 ft-lbs)+75°