GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Grand Am 🢒 Engine 🢒 Engine Mechanical - 3.4L 🢒 Engine Front Cover Replacement

Removal Procedure
  1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  2. Remove the oil pan. Refer to Oil Pan Replacement .

    3. Object Number: 54378 Size: SH
  3. Remove the crankshaft position (CKP) sensor. Refer to Crankshaft Position Sensor Replacement in Engine Controls - 3.4L.
  4. Remove the lower front cover bolts.
  5. Lower the vehicle.

    6. Object Number: 63031 Size: SH
  6. Remove the engine mount . Refer to Engine Mount Replacement - Right Side .
  7. Remove the engine mount bracket support.
  8. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  9. Loosen water pump pulley bolts.
  10. Remove the drive belt. Refer to Drive Belt Replacement .
  11. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  12. Remove water pump pulley bolts and pulley.
  13. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  14. Remove the lower radiator hose to coolant outlet housing.

    15. Object Number: 54375 Size: SH
  15. Remove the upper front cover bolts (2).
  16. Remove the front cover.
  17. Remove the front cover oil seal.
  18. Clean the mating surfaces of the following items:
    19. • The front cover
    • The oil pan
    • The cylinder block
  19. Clean the sealing surfaces using degreaser.

Installation Procedure
  1. Install the front cover gasket.

    2. Object Number: 54375 Size: SH
  2. Place the front cover on the engine.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the medium length cover bolts (2).

    4. Tighten
    Tighten the bolts to 55 N·m (41 lb ft).

  4. Install the lower radiator hose to coolant housing.
  5. Install the thermostat bypass pipe . Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  6. Raise the vehicle.
  7. Install the front cover lower bolts (1).

    8. Tighten

        • Tighten the front cover small bolts (1) to 27 N·m (20 lb ft).
        • Tighten the front cover large bolts (2) to 55 N·m (41 lb ft).

    Object Number: 54378 Size: SH
  8. Install the CKP sensor. Refer to Crankshaft Position Sensor Replacement in Engine Controls - 3.4L.
  9. Install crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  10. Lower the vehicle.
  11. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  12. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  13. Install water pump pulley and bolts.
  14. Install drive belt. Refer to Drive Belt Replacement .

    15. Object Number: 63031 Size: SH
  15. Install the engine mount. Refer to Drive Belt Replacement .

    16. Tighten
    Tighten water pump pulley bolts to 25 N·m (19 lb ft).

  16. Install oil pan. Refer to Oil Pan Replacement .
  17. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.