Spark

Engine Front Cover with Oil Pump Replacement - with CH-49290

Special Tools

For equivalent regional tools, refer to Special Tools .

1. Open the bonnet.

Warning: Refer to Battery Disconnect Warning in the Preface section.

2. Disconnect the negative battery cable.
3. Drain the cooling system. Refer to Cooling System Draining and Filling .
4. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement .
5. Remove the camshaft cover. Refer to Camshaft Cover Replacement .
6. Remove the oil dipstick and tube. Refer to Oil Level Indicator Tube Replacement .
7. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle .
8. Remove the sump. Refer to Sump Replacement .
9. Remove the drive belt. Refer to Drive Belt Replacement .
10. Remove the water pump. Refer to Water Pump Replacement .
11. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal .
12. Remove the generator. Refer to Generator Replacement .
13. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Removal .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.

14. Assemble the CH-49290 engine support tool (1) according to the details provided in the SPX installation manual.
15. Install the torque support (2) to the engine.
16. Support the CH-904 base frame on a jack.
17. Support the CH-49290 engine support tool on the CH-904 base frame .




Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly.

18. Install the CH-49290 engine support tool (1) according to the details provided in the SPX installation manual.



19. Remove the engine mount bolts (1, 3) and nuts (2).
20. Remove the engine mount (4).



21. Remove the engine front cover bolts (2, 3, 4).




Note: Use the pry points and a bolt in the jackscrew hole in order to remove the engine front cover.

22. Using the pry points (1) located at the edge of the front cover, shear the room temperature vulcanising (RTV) sealant.
23. Remove the engine front cover evenly all the way around with a suitable tool. Refer to Engine Front Cover and Oil Pump Removal .

Note: There are no serviceable components within the oil pump. Disassemble the pump only to diagnose an oiling concern. A disassembled oil pump must not be reused. A disassembled oil pump must be replaced.

24. Disassemble the engine front cover as necessary. Refer to Oil Pump Disassemble .

Note: DO NOT use sharp and/or metal gasket scrapers in order to clean the sealing surfaces.

1. Carefully clean the engine front cover sealing surfaces.
2. Assemble the engine front cover as necessary. Refer to Oil Pump Assemble .



3. Apply an approximately 3.5 mm (0.14 in) thick bead of oil pan sealant
4. Install the engine front cover.




Note: Do not damage the sealing surfaces.

5. Install the engine front cover with the included oil pump (1).

Caution: Refer to Fastener Caution in the Preface section.

Note: Check the different screw lengths.

6. Tighten the bolts (2, 3, 4) to 20 N·m (15 lb ft).



7. Install the engine mount (4).
8. Install the bolts (1, 3) and nuts (2).
9. Tighten the engine mount to body retaining bolts (1) to 50 N·m (37 lb ft).
10. Tighten the engine mount to engine retaining bolt (3) and nuts (2) to 58 N·m (43 lb ft).



11. Remove the CH-49290 engine support tool (1).
12. Remove the CH-49290 engine support tool from the CH-904 base frame .
13. Remove the CH-904 base frame from the jack.



14. Disassemble the CH-49290 engine support tool (1).
15. Remove the torque support (2) from the engine.
16. Install the drive belt tensioner. Refer to Drive Belt Tensioner Installation .
17. Install the generator. Refer to Generator Replacement .
18. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation .
19. Install the water pump. Refer to Water Pump Replacement .
20. Install the drive belt. Refer to Drive Belt Replacement .
21. Install the oil pan. Refer to Sump Replacement .
22. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
23. Install the engine oil dipstick and tube. Refer to Oil Level Indicator Tube Replacement .
24. Install the camshaft cover. Refer to Camshaft Cover Replacement .
25. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
26. Fill the engine oil, if necessary.
27. Fill the cooling system. Refer to Cooling System Draining and Filling .
28. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
29. Close the bonnet.