Timing Cover: Service and Repair

REMOVAL PROCEDURE

^ Tools Required
- J 37096 Flywheel Holder





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
2. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36 (VIN K)) or to Drive Belt Tensioner Replacement (L67 (VIN 1)).
4. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
5. Disconnect the wiring harness connectors from the engine front cover.
6. Remove the crankshaft position sensor shield.





7. Install the J28467-90A and the J28467-B. Refer to Engine Support Fixture.

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.

8. Remove the engine mount bracket for oil pan access. Refer to Engine Mount Bracket Replacement.
9. Lower the oil pan and remove the oil pan-to-engine front cover bolts.
10. Drain the engine oil. Remove the oil filter. Refer to Engine Oil and Oil Filter Replacement.
11. Remove the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet (3800 Engine) in Cooling System.
12. Remove the water pump pulley. Refer to Water Pump Replacement (3800 Engine) in Cooling System.





13. Remove the crankshaft position sensor.





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





16. Remove the engine front cover gasket.
17. 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 Valve Assembly Replacement.
18. If replacing the engine front cover, remove the water pump from the engine front cover. Refer to Water Pump Replacement (3800 Engine) in Cooling System.





19. 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.
20. Inspect the oil pump cover and gear set. Refer to Oil Pump Clean and Inspect in Unit Repair.





21. If replacing the engine front cover, remove the camshaft position sensor from the engine front cover.
22. Inspect the timing chain for overall in and out movement. Maximum movement is 25.4 mm (1 inch). Refer to Timing Chain and Sprockets Clean and Inspect (VIN K) or Timing Chain and Sprockets Clean and Inspect (VIN 1) in Unit Repair.
23. Inspect the sprockets for wear.
24. Clean the mating surfaces of the front cover and cylinder block.
25. Clean the sealing surfaces with degreaser.

INSTALLATION PROCEDURE

^ Tools Required
- J 36660 Electronic Torque Angle Meter
- J 37096 Flywheel Holder

NOTICE: Refer to Fastener Notice in Service Precautions.





1. If replacing the engine front cover, install the camshaft position sensor to the engine front cover.
^ Tighten the camshaft position sensor bolts to 10 Nm (89 inch lbs.).





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 Valve Assembly Replacement.
4. If replacing the engine front cover, install the water pump to the engine front cover. Refer to Water Pump Replacement (3800 Engine) in Cooling System.





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 the 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 Camshaft Position Sensor Replacement in Powertrain Management.





11. Install the engine front cover bolts (1 - 7).
^ Tighten the engine front cover bolts to 20 Nm (15 ft. lbs.). Use the J 36660 in order to rotate the bolts an additional 40 degrees.

12. Inspect the oil pan gasket. Replace the gasket if necessary.
13. Install the oil pan-to-engine front cover bolts and the oil pan bolts.
^ Tighten the oil pan-to-engine front cover bolts to 14 Nm (125 inch lbs.).

14. Install the engine mount bracket. Refer to Engine Mount 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 (3800 Engine) in Cooling System.
19. Connect the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet (3800 Engine) in Cooling System.





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 (L36 (VIN K)) or Drive Belt Tensioner Replacement (L67 (VIN 1)).
25. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
26. Fill the crankcase with clean engine oil. Refer to Specifications.
27. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
28. Inspect for proper fluid levels.
29. Inspect for leaks.