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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 557 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Engine Front Cover Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  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) 

    Fig 1: Camshaft Position Sensor
    G01764215Courtesy of GENERAL MOTORS CORP.
  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 .
    Fig 2: Oil Pump Cover And Gear Set To The Engine Front Cover
    G01764216Courtesy of GENERAL MOTORS CORP.
  3. If replacing the engine front cover, install the water pump.
  4. Install the water pump bolts.

    Tighten: 

    Tighten the water pump bolts in the following sequence: 

    • Tighten the long water pump bolts to 20 N.m (15 lb ft).
    • Tighten the short water pump bolts to 15 N.m (11 lb ft).
      • Fig 3: Water Pump Bolts
      G01764217Courtesy of GENERAL MOTORS CORP.

  5. If replacing the engine front cover, install the pressure relief valve, the oil filter adapter and the oil filter adapter bolts to the engine front cover.

    Tighten: 

    Tighten the bolts to 30 N.m (22 lb ft) 

    Fig 4: Pressure Relief Valve, The Oil Filter Adapter And The Oil Filter Adapter Bolts
    G01764218Courtesy of GENERAL MOTORS CORP.
  6. Install the new engine front cover gasket. Ensure that the sealing surfaces are not damaged.
  7. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolt threads.
    Fig 5: Engine Front Cover Gasket
    G01764219Courtesy of GENERAL MOTORS CORP.
  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 to the engine.
    Fig 6: Engine Front Cover
    G01764220Courtesy of GENERAL MOTORS CORP.
  10. Install the engine front cover bolts (1-7).

    Tighten: 

    Tighten the bolts to 34 N.m (25 lb ft) 

    Fig 7: Engine Front Cover Bolts
    G01764221Courtesy of GENERAL MOTORS CORP.
  11. Install the crankshaft position sensor.

    Tighten: 

    Tighten the crankshaft position sensor studs to 30 N.m (22 lb ft) 

    Fig 8: Crankshaft Position Sensor
    G01764222Courtesy of GENERAL MOTORS CORP.
  12. Install the new engine front cover seal using J 35354.
  13. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover.
  14. Remove the J 35354.
    Fig 9: Install The New Engine Front Cover Seal Using J 35354
    G01764223Courtesy of GENERAL MOTORS CORP.
  15. Install the oil pan-to-engine front cover bolts.

    Tighten: 

    Tighten the oil pan bolts to 14 N.m (125 lb in) 

  16. Install the oil level sensor.

    Tighten: 

    Tighten the sensor to 20 N.m (15 lb ft) 

  17. Connect the oil level sensor electrical connector.
  18. Install the engine mount bracket. Refer to Engine Mount and Bracket Replacement .
  19. Install the water pump pulley and bolts.

    Tighten: 

    Tighten the bolts to 13 N.m (116 lb in) 

  20. Install the radiator outlet hose to the water pump. Refer to or RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) in ENGINE COOLING .
  21. Install the oil filter. Install the engine oil pan drain plug. Refer to Engine Oil and Oil Filter Replacement .
    Fig 10: Oil Filter
    G01764224Courtesy of GENERAL MOTORS CORP.
  22. Install the crankshaft position sensor shield.
  23. Connect the electrical connectors to the following:
    • Oil pressure sensor.
    • Crankshaft position (CKP) sensor
    • Camshaft position (CMP) sensor
  24. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  25. Lower the vehicle.
  26. Remove the engine support fixture.
  27. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67)  .
  28. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in ENGINE COOLING .
  29. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  30. Connect the negative battery cable.
  31. Inspect for leaks.
  32. Perform the CKP system variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR SYSTEM VARIATION L
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