Tools Required

1. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
2. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
3. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
4. Disconnect the wiring harness connectors from the engine front cover.



5. Remove the crankshaft position sensor shield.




Important: The oil pan can be dropped slightly for engine front cover clearance if all pan bolts are loosened and the oil level sensor is removed.

6. Install the J 28467-90A and the J 28467-B . Refer to Engine Support Fixture .
7. Remove the engine mount bracket for oil pan access. Refer to Engine Mount and Bracket Replacement .
8. Lower the oil pan and remove the oil pan-to-engine front cover bolts.
9. Drain the engine oil. Remove the oil filter. Refer to Engine Oil and Oil Filter Replacement .
10. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
11. Remove the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.



12. Remove the crankshaft position sensor.



13. Remove the engine front cover attaching bolts.
14. Remove the engine front cover with the oil filter adapter as one assembly.



15. Remove the engine front cover gasket.
16. If replacing the engine front cover, remove the oil filter adapter and pressure relief valve from the engine front cover. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
17. If replacing the engine front cover, remove the water pump from the engine front cover. Refer to Water Pump Replacement in Engine Cooling.



18. If replacing the engine front cover, remove the oil pump cover and gear set from the engine front cover. Refer to Oil Pump Cover and Gear Set Replacement .
19. Inspect the oil pump cover and gear set. Refer to Oil Pump Cleaning and Inspection .



20. If replacing the engine front cover, remove the camshaft position sensor from the engine front cover.
21. Inspect the timing chain for overall in and out movement. Maximum movement is 25.4 mm (1 in). Refer to Camshaft Timing Chain and Sprocket Cleaning and Inspection .
22. Inspect the sprockets for wear.
23. Clean the mating surfaces of the front cover and cylinder block.
24. Clean the sealing surfaces with degreaser.

Tools Required

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. If replacing the engine front cover, install the camshaft position sensor to the engine front cover.

Tighten
Tighten the camshaft position sensor bolts to 10 N·m (89 lb in).




2. If replacing the engine front cover, install the oil pump cover and gear set to the engine front cover. Refer to Oil Pump Cover and Gear Set Replacement .
3. If replacing the engine front cover, install the oil filter adapter and pressure relief valve to the engine front cover. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
4. If replacing the engine front cover, install the water pump to the engine front cover. Refer to Water Pump Replacement in Engine Cooling.



5. Install the new engine front cover seal. Refer to Crankshaft Front Oil Seal Replacement .



6. Install the new engine front cover gasket. Ensure that the sealing surfaces are not damaged.
7. Apply sealer GM P/N 1052080 or equivalent to the bolt threads.



8. Align the cogs on the crankshaft sprocket with the cogs on the oil pump gear set in the engine front cover.
9. Install the engine front cover on the engine.



10. Install the crankshaft position sensor. Refer to Crankshaft Position Sensor Replacement in Engine Controls - 3.8L.



11. Install the engine front cover bolts (1-7).

Tighten
Tighten the engine front cover bolts to 20 N·m (15 lb ft). Use the J 36660-A in order to rotate the bolts an additional 40 degrees.

12. Inspect the oil pan gasket. Replace if necessary.
13. Install the oil pan-to-engine front cover bolts and the oil pan bolts.

Tighten
Tighten the oil pan-to-engine front cover bolts to 14 N·m (125 lb in).

14. Install the engine mount bracket. Refer to Engine Mount and Bracket Replacement .
15. Lower the engine.
16. Install the engine mount bracket bolts.
17. Remove the J 28467-B and the J 28467-90A .
18. Install the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.
19. Connect the radiator outlet hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.



20. Install the oil filter. Install the engine oil pan drain plug. Refer to Engine Oil and Oil Filter Replacement .



21. Install the crankshaft position sensor shield.
22. Connect the wiring harness connectors to the engine front cover.
23. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
24. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
25. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
26. Fill the crankcase with clean engine oil. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
27. Inspect for proper fluid levels.
28. Inspect for leaks.
29. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.8L.