GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Timing Chain Front Cover

Print

REMOVAL & INSTALLATION



2.2L Engine

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Crankshaft pulley and hub removal and installation-2.2L engine



Click image to see an enlarged view

Fig. Fig. 2: Timing chain cover removal and installation-2.2L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the right side tire and wheel assembly. Mark a relationship between the wheel and the wheel stud for reinstallation purposes.
  8.  
  9. Unfasten the crankshaft pulley bolts, then remove the pulley.
  10.  
  11. Install puller J 24420-B or equivalent and remove the hub.
  12.  
  13. Remove the electrical center cover.
  14.  
  15. Remove the serpentine belt tensioner and bracket.
  16.  
  17. Remove the oil pan, as outlined earlier in this information.
  18.  
  19. Unfasten the timing chain cover bolts, then remove the cover. If the cover is difficult to removed, use a rubber mallet to carefully loosen the cover. Remove and discard the timing chain cover gasket.
  20.  
  21. Thoroughly clean all gasket mating surfaces.
  22.  

To install:
  1. Position the timing chain cover to the engine, using a new gasket, guiding the cover over the dowel pins.
  2.  
  3. Install the timing chain cover retaining bolts, then tighten to 97 inch lbs. (11 Nm).
  4.  
  5. Install the crankshaft pulley hub using tool J 29113 or equivalent, and using RTV sealant at the keyway in the crankshaft.
  6.  
  7. Install the oil pan, as outlined earlier in this information.
  8.  
  9. Install the crankshaft belt pulley, then tighten the retaining bolts to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the crankshaft hub bolt, then tighten to 77 ft. lbs. (105 Nm).
  12.  
  13. Install the serpentine belt and the electrical cover.
  14.  
  15. Install the right side inner wheel well splash shield.
  16.  
  17. Install the the wheel and tire assembly, then carefully lower the vehicle.
  18.  
  19. Tighten the lug nuts to specification, then connect the negative battery cable.
  20.  
  21. Fill the crankcase to the correct level with the proper type of oil.
  22.  
  23. Start the engine and check for proper operation and/or leakage.
  24.  

2.3L Engine

See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: Timing chain cover-2.3L engine

  1. Disconnect the negative battery cable. Remove the coolant recovery reservoir.
  2.  
  3. Remove the serpentine drive belt using a 13mm wrench that is at least 24 in. (61cm) long.
  4.  
  5. Remove upper cover fasteners.
  6.  
  7. Disconnect the cover vent hose.
  8.  
  9. Remove the engine lift bracket.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the right front wheel assembly and lower splash shield.
  14.  
  15. Remove the crankshaft balancer assembly.
  16.  
  17. Detach the lower cover fasteners.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Remove the timing chain front cover and gaskets. Discard the gaskets.
  22.  

To install:
  1. Install the cover and new gaskets. Place the nuts on the studs to retain the cover, then install the bolts and tighten to 106 inch lbs. (12 Nm).
  2.  
  3. Install the engine lift bracket.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the remaining cover fasteners and tighten to 106 inch lbs. (12 Nm).
  8.  
  9. Lubricate the front oil seal and the sealing surface of the crankshaft balancer with a suitable chassis grease.
  10.  
  11. Install the crankshaft balancer and tighten the balancer retaining bolt to 74 ft. lbs. (100 Nm) plus an additional 90ºturn.
  12.  
  13. Install the right front wheel and tire assembly.
  14.  
  15. Carefully lower the vehicle.
  16.  


CAUTION
To avoid personal injury when rotating the serpentine belt tensioner, use a tight fitting 13mm wrench that is at least 24 inches (61cm) long.

  1. Install the serpentine drive belt.
  2.  
  3. Attach the cover vent hose.
  4.  
  5. Install the coolant recovery tank.
  6.  
  7. Connect the negative battery cable, then start the engine and check for leaks.
  8.  

2.5L Engine

See Figure 4



Click image to see an enlarged view

Fig. Fig. 4: Timing chain cover-2.5L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the torque strut bolt at the cylinder head bracket and move the strut out of the way.
  4.  
  5. Remove the serpentine belt.
  6.  
  7. Install the engine support fixture tool J-28467-A and J-36462.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the right front tire assembly.
  12.  
  13. Disconnect the right lower ball joint from the knuckle.
  14.  
  15. Remove the 2 right frame attaching bolts.
  16.  
  17. Loosen the 2 left frame attaching bolts but do not remove.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Lower the engine on the right side. Raise and safely support the vehicle.
  22.  
  23. Remove the engine vibration dampener using a suitable dampener puller.
  24.  
  25. Unfasten the timing cover retaining bolts, then remove the cover. Remove and discard the gasket.
  26.  

To install:
  1. Clean all gasket mating surfaces with solvent and a gasket scraper.
  2.  
  3. Apply a 3 / 8 in. (10mm) wide by 1 / 16 in. (1.6mm) thick bead of RTV sealer to the joint at the oil pan and timing cover.
  4.  
  5. Apply a 1 / 4 in. (6mm) wide by 1 / 8 in. (3mm) thick bead of RTV sealer to the timing cover at the block mating surface.
  6.  
  7. Install a new timing cover oil seal using a timing cover seal installer tool J-34995 or equivalent.
  8.  
  9. Position the cover onto the block and install the retaining bolts loosely.
  10.  
  11. Install the timing cover seal installer tool J-34995 to align the timing cover.
  12.  
  13. Tighten the opposing bolts to hold the cover in place.
  14.  
  15. Tighten the bolts, in sequence, to 89 inch lbs. (10 Nm). Remove the timing cover oil seal installer tool.
  16.  
  17. Install the crankshaft vibration dampener and tighten the bolt to 162 ft. lbs. (220 Nm)
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Raise the engine to its proper position using the support fixture.
  22.  
  23. Raise and safely support the vehicle.
  24.  
  25. Raise the frame and install the removed frame bolts. Tighten the bolts to 103 ft. lbs. (140 Nm)
  26.  
  27. Install the right ball joint, then tighten the nut.
  28.  
  29. Install the right front tire, tighten the lug nuts to 100 ft. lbs. (136 Nm) and lower the vehicle.
  30.  
  31. Remove the engine support fixture.
  32.  
  33. Install the torque strut and bolt to the cylinder head bracket.
  34.  
  35. Install the serpentine belt, connect the negative battery cable and check for oil leaks.
  36.  

2.8L and 3.1L Engines
VEHICLES THROUGH 1993

See Figure 5

Click image to see an enlarged view

Fig. Fig. 5: Timing chain front cover removal-1993 3.1L engine shown

  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the negative battery cable. Drain the cooling system into a suitable container.
  4.  
  5. Remove the serpentine belt and the belt tensioner.
  6.  
  7. Remove the alternator-to-bracket bolts and remove the alternator, with the wires attached, then support it out of the way.
  8.  
  9. Unfasten the power steering pump-to-bracket bolts and support it out of the way. Do not disconnect the pressure hoses.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the right side inner fender splash shield. Remove the flywheel dust cover.
  14.  
  15. Using a suitable crankshaft pulley puller tool, remove the crankshaft damper.
  16.  
  17. Label and disconnect the starter wires, then remove the starter.
  18.  
  19. Drain the engine oil into a suitable container, then remove the oil pan.
  20.  
  21. Remove the lower front cover bolts.
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Disconnect the radiator hose from the water pump.
  26.  
  27. Detach the heater coolant hose from the cooling system filler pipe.
  28.  
  29. Remove the bypass and overflow hoses.
  30.  
  31. Remove the water pump pulley. Disconnect the canister purge hose.
  32.  
  33. Remove the spark plug wire shield from the water pump.
  34.  
  35. Unfasten the upper front cover-to-engine bolts, then remove the front cover.
  36.  
  37. Remove and discard the gasket. Clean front cover mounting surfaces.
  38.  

To install:
  1. Apply a thin bead of silicone sealant on the front cover mating surface and using a new gasket, install the front cover on the engine with the top bolts to hold it in place.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Install the oil pan. Install the lower front cover bolts, tighten all of the front cover bolts to 26-35 ft. lbs. (35-48 Nm).
  6.  
  7. Install the serpentine belt and idler pulley. Install the damper on the engine using tool J-29113 or equivalent. Install the starter.
  8.  
  9. Install the inner fender splash shield. Lower the vehicle.
  10.  
  11. Attach the radiator hose to the water pump and attach the heater hoses.
  12.  
  13. Install the power steering pump and the alternator.
  14.  
  15. Attach the spark plug wire shield. Fill the cooling system.
  16.  
  17. Connect the negative battery cable. Check for coolant and oil leaks.
  18.  

1994-96 VEHICLES

See Figure 6

Click image to see an enlarged view

Fig. Fig. 6: Engine front cover removal and installation-1996 3.1L engine shown

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a suitable container.
  4.  
  5. Remove the serpentine drive belt.
  6.  
  7. With the help of an assistant, remove the hood.
  8.  
  9. Remove the engine mount strut and A/C compressor bracket and the engine mount strut bracket.
  10.  
  11. Remove the electric cooling fan.
  12.  
  13. Install engine support tools J 28467-A and J 36462, or equivalent.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Remove the front exhaust manifold pipe.
  18.  
  19. Unfasten the intermediate steering shaft bolt/screw, then position the cover aside.
  20.  
  21. Drain the engine oil into a suitable container.
  22.  
  23. Remove the engine splash shield.
  24.  
  25. Remove the crankshaft balancer bolt/screw and washer, then remove the balancer using tool J 24420-B or equivalent.
  26.  
  27. Support the drivetrain and front suspension frame with suitable jackstands.
  28.  
  29. Remove the transaxle mount side frame retaining nuts from the drivetrain and suspension frame assembly.
  30.  
  31. Remove the engine mount side frame nuts from the drivetrain and suspension frame assembly.
  32.  
  33. Unfasten the rear drivetrain and front suspension frame bolts/screws.
  34.  
  35. If equipped, remove the lower drivetrain and front suspension frame bolts/screws.
  36.  
  37. Remove the engine mount assembly.
  38.  
  39. Remove the flywheel inspection cover.
  40.  
  41. Remove the starter, as outlined in Engine Electrical of this repair guide.
  42.  
  43. Disconnect the transaxle mount assembly from the oil pan.
  44.  
  45. Unfasten the side bolts and screws and the retaining bolts and screws, then remove the oil pan.
  46.  
  47. Raise the drivetrain and front suspension frame, then install the retaining bolts/screws.
  48.  
  49. Carefully lower the vehicle.
  50.  
  51. Remove the coolant recovery reservoir.
  52.  
  53. Remove the serpentine drive belt shield.
  54.  
  55. Remove the power steering pump pulley.
  56.  
  57. Unfasten the power steering pump bolts, then position the pump aside. Do NOT disconnect the fluid lines.
  58.  
  59. Remove the thermostat bypass pipe clip nut from the upper intake manifold, then disconnect the pipe from the water pump.
  60.  
  61. Remove the water pump pulley.
  62.  
  63. Disconnect the lower radiator outlet hose from the water pump.
  64.  
  65. Remove the serpentine drive belt tensioner.
  66.  
  67. Remove the Crankshaft Position (CKP) sensor from the front cover.
  68.  
  69. Unfasten the front cover retaining bolts, and screws, then remove the front cover and gasket. Discard the gasket.
  70.  
  71. Remove the water pump from the front cover.
  72.  

To install:
  1. Thoroughly clean all the gasket mating surfaces.
  2.  
  3. Install the water pump to the front cover.
  4.  
  5. Coat both sides of the lower tabs of a new cover gasket with sealer 1052080 or equivalent. Position the gasket in the front cover, then install the cover and secure with the bolts and screws. Tighten the large bolts and screws to 35 ft. lbs. (47 Nm). and the small bolts/screws to 15 ft. lbs. (20 Nm).
  6.  
  7. Attach the crankshaft position sensor to the front cover.
  8.  
  9. Install the serpentine drive belt tensioner.
  10.  
  11. Connect the lower radiator outlet hose to the water pump.
  12.  
  13. Install the water pump pulley.
  14.  
  15. Attach the thermostat bypass pipe to the water pump and secure with the nut to the upper intake manifold.
  16.  
  17. Position the power steering pump and secure with the retaining bolts. Install the power steering pump pulley.
  18.  
  19. Install the serpentine belt shield.
  20.  
  21. Install the coolant recovery reservoir.
  22.  
  23. Raise and safely support the vehicle.
  24.  
  25. Safely support the drivetrain and front suspension frame with jackstands.
  26.  
  27. Remove the rear drivetrain and front suspension bolts/screws.
  28.  
  29. Carefully lower the drivetrain and front suspension frame.
  30.  
  31. Install the oil pan, as outlined earlier in this information.
  32.  
  33. Fasten the transaxle mount to the oil pan.
  34.  
  35. Install the starter and the flywheel cover.
  36.  
  37. Install the engine mount.
  38.  
  39. Raise the drivetrain and front suspension frame.
  40.  
  41. Install the rear drivetrain and front suspension frame retaining bolts/screws.
  42.  
  43. Fasten the engine mount frame side nuts to the drivetrain and front suspension frame.
  44.  
  45. Remove the jackstands from the drivetrain and front suspension frame.
  46.  
  47. Install the crankshaft balancer. Tighten the retaining washer and bolt/screw to 76 ft. lbs. (103 Nm).
  48.  
  49. Fasten the engine splash shield.
  50.  
  51. Install the intermediate steering shaft bolt/screw and cover.
  52.  
  53. Connect the front exhaust pipe.
  54.  
  55. Carefully lower the vehicle.
  56.  
  57. Remove the engine support fixtures.
  58.  
  59. Install the electric cooling fan.
  60.  
  61. Install the engine mount strut and A/C compressor bracket and the engine mount strut bracket.
  62.  
  63. With the help of an assistant, install the hood.
  64.  
  65. Install the serpentine drive belt.
  66.  
  67. Refill all necessary fluids.
  68.  
  69. Connect the negative battery cable.
  70.  

3.4L Engines

See Figures 7 and 8



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of the front cover removal-3.4L engine



Click image to see an enlarged view

Fig. Fig. 8: Front cover bolt locations-3.4L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove secondary timing belt tensioner mounting bracket and gasket by removing tensioner pulley and mounting bracket bolts.
  4.  
  5. For 1992-96 vehicles, remove the secondary timing belt, as outlined later in this information. Remove secondary timing belt idler pulleys.
  6.  
  7. Remove the front engine lift hook/bracket.
  8.  
  9. Remove engine torque strut mount bracket to frame bolts and position strut out of the way.
  10.  
  11. Unfasten the cooling fan bolts, then remove the uppoer radiator support. For 1991 vehicles, remove the right side cooling fan and for 1992-96 vehicles remove both cooling fans.
  12.  
  13. Properly drain the cooling system into a suitable container, then disconnect the lower radiator hose from coolant pump inlet pipe.
  14.  
  15. For vehicles equipped with a manual transaxle, disconnect the front air hose at the air pipe.
  16.  
  17. Detach the heater hose from the front cover and remove the heater pipe bracket retainer bolts at frame.
  18.  
  19. Raise and safely support vehicle. Drain the engine oil into a suitable container.
  20.  
  21. Remove right front tire and wheel assembly. Remove right splash shield.
  22.  
  23. Remove crankshaft pulley and damper.
  24.  
  25. Remove the oil filter.
  26.  
  27. For 1992-96 vehicles, remove the engine oil cooler assembly.
  28.  
  29. For 1992-96 vehicles, remove the front oil pan retaining nuts (2) and bolts (4). Loosen, but do not remove the remaining pan bolts.
  30.  
  31. If equipped, remove the A/C compressor mounting bracket bolts.
  32.  
  33. Remove the lower front cover bolts.
  34.  
  35. On vehicles equipped with an automatic transaxle vehicles, remove the halfshaft.
  36.  
  37. Remove the rear alternator bracket, then remove the starter motor. Carefully lower the vehicle.
  38.  
  39. Remove the camshaft drive belt sprocket retaining bolt, then extract the camshaft drive belt sprocket using tool J-38616 or equivalent.
  40.  
  41. Remove upper alternator retaining bolts. Unfasten the forward light relay center screws, then position the relay center aside.
  42.  
  43. Disconnect the oil cooler hose from the front cover, then remove the water pump pulley.
  44.  
  45. If equipped with a manual transaxle, remove the secondary air injection pipe check valve.
  46.  
  47. Unfasten the upper front cover bolts, then remove the front cover. Remove and discard the old gasket, then clean the mating surfaces of front cover and block.
  48.  

To install:
  1. Apply GM sealer 1052080 or equivalent, to lower edges of the sealing surface of the front cover and place the cover in position. Apply thread sealant to the large retaining bolts and secure the cover in place. Do not tighten the cover bolts at this time.
  2.  
  3. If equipped, install the secondary air injection pipe check valve.
  4.  
  5. Install the water pump pulley. Connect the oil cooler coolant hose to front cover.
  6.  
  7. Install the forward light relay center and upper alternator retaining bolts.
  8.  
  9. Install the camshaft drive belt sprocket secure the retaining bolt using tool J 31096, or equivalent.
  10.  
  11. Raise and safely support vehicle.
  12.  
  13. Install the starter motor, as outlined in Engine Electrical of this repair guide.
  14.  
  15. For vehicles equipped with an automatic transaxle, install the halfshaft.
  16.  
  17. Install the rear alternator bracket.
  18.  
  19. Install the lower front cover bolts and tighten to 18 ft. lbs. (25 Nm).
  20.  
  21. Install the A/C compressor mounting bolts.
  22.  
  23. If removed, install the oil pan retaining nuts and bolts. Tighten the rear bolts to 18 ft. lbs. (25 Nm) and the remaining bolts and nuts to 89 inch lbs. (10 Nm).
  24.  
  25. Install the oil filter and the crankshaft damper and pulley.
  26.  
  27. If equipped with a manual transaxle, remove the front-to-rear engine mount bracket brace.
  28.  
  29. For 1992-96 vehicles, install the engine oil cooler and hoses.
  30.  
  31. Fasten the right side splash shield and the wheel and tire assembly. Carefully lower the vehicle.
  32.  
  33. Install and tighten the upper front cover small bolts to 18 ft. lbs. (25 Nm), and the front cover large bolts to 35 ft. lbs. (47 Nm).
  34.  
  35. Connect the heater hoses to the front cover and attach the lower radiator hose to the water pump.
  36.  
  37. If equipped connect the secondary air injection hose to the front exhaust manifold air injection pipe.
  38.  
  39. Install the coolant fans. Add coolant to the correct level.
  40.  
  41. Install the retainer screws into heater pipe bracket.
  42.  
  43. Install the upper radiator support and the torque strut-to-frame bolts.
  44.  
  45. Install front engine lift hook and secondary timing belt idler pulley.
  46.  
  47. For 1992-96 vehicles, install the secondary timing belt, as outlined later in this information. Install the secondary timing belt tensioner mounting bracket. Tighten the bolts to 37 ft. lbs. (50 Nm).
  48.  
  49. Connect the negative battery cable.
  50.  

3.8L Engine

See Figure 9



Click image to see an enlarged view

Fig. Fig. 9: Timing chain front cover removal and installation-3.8L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the crankshaft balancer.
  4.  
  5. Remove the crankshaft sensor cover.
  6.  
  7. Tag and detach the electrical connections from the camshaft, crankshaft and oil pressure sensors.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Drain the engine oil into a suitable container, then remove the oil pan-to-front cover bolts.
  12.  
  13. Remove the oil filter, then disconnect the oil cooler pipes from the oil filter adapter housing.
  14.  
  15. Carefully lower the vehicle and drain the cooling system into a suitable container.
  16.  
  17. Remove the alternator and brace.
  18.  
  19. Disconnect the heater hoses, the pipe, and the bypass hose from the cover.
  20.  
  21. Detach the lower radiator hose.
  22.  
  23. Remove the water pump pulley.
  24.  
  25. Unfasten the front cover attaching bolts, then remove the cover with the oil filter adapter as an assembly.
  26.  
  27. Remove the oil filter adapter housing.
  28.  
  29. Remove the oil pressure valve, spring and oil pump from the front cover.
  30.  
  31. Remove the water pump from the front cover.
  32.  
  33. Carefully pry the oil seal out of the cover using a suitable tool.
  34.  

To install:

The oil pan bolts can be loosened and the pan dropped slightly for front cover clearance. If the oil pan gasket is excessively swollen, the oil pan must be removed and the gasket replaced.

  1. Clean the mating surfaces of the front cover and cylinder block with a degreaser.
  2.  
  3. Install the oil filter and adapter housing with the oil pressure valve and spring to the cover. Tighten the bolts to 24 ft. lbs. (32 Nm).
  4.  
  5. Install the oil pump assembly to the cover.
  6.  
  7. Use a new gasket, apply sealer to the bolt threads and install the coolant pump to the front cover.
  8.  
  9. Lubricate a new front cover oil seal with clean engine oil and install it to the front cover, using tool J-35354 or equivalent. Use the crankshaft balancer bolt with the tool and tighten the bolt until the seal is seated in the cover. Remove the tool.
  10.  
  11. Install the front cover to the engine and install the upper cover bolts. Tighten the upper cover bolts to 124 inch lbs. (14 Nm)
  12.  
  13. Install the crankshaft sensor and adjust, using tool J-37089 or equivalent.
  14.  
  15. Fasten the sensor cover and attach the electrical connections, as tagged during removal.
  16.  
  17. Install the crankshaft balancer.
  18.  
  19. Connect the oil cooler lines, then install the oil filter.
  20.  
  21. Carefully lower the vehicle, then install the water pump pulley.
  22.  
  23. Connect the lower radiator hose, bypass hose and heater hoses.
  24.  
  25. Install the alternator and brace.
  26.  
  27. Add the proper types and amount of coolant and engine oil.
  28.  
  29. Connect the negative battery cable.
  30.  

 
label.common.footer.alt.autozoneLogo