Oil Pump Replacement (Second Design)

REMOVAL PROCEDURE

Second Design Oil Pump and Rear Timing Belt Cover Information
Starting with engine unit number 08191279, a second design oil pump housing and rear timing belt cover were introduced into MY97 Catera production. The second design rear timing belt cover features an additional hole that allows access to one of the oil pump bolts located behind the cover. Since it is necessary to re-torque all of the oil pump bolts after the timing belt idler pulley installation, the access hole was added to the cover to make the re-torque procedure easier. The second design oil pump has an extended boss to shield the access hole in the rear timing belt cover from road and other debris. Both first and second design pumps use the same gaskets. Second design pumps can be installed on first design engines, however, it requires the use of the second design rear timing belt cover and a longer (M6 x 25 mm) oil pump bolt in the number six position.

- TOOLS REQUIRED
- J 35268-A Camshaft/Front Main Seal Installer
- J 36660 Torque/Angle Meter
- J 42098 Crank Hub Torx Socket
- J 42065 Crank Hub Holding Tool

1. Disconnect the negative battery cable.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Recover the A/C system.
3. Drain the coolant.
4. Remove the intake air resonator.
5. Remove the front timing belt cover.
6. Remove the timing belt.
7. Remove the rear timing belt cover.
8. Remove the A/C compressor.
9. Remove the A/C compressor and power steering pump bracket bolts.
10. Position the A/C compressor and power steering pump bracket out of the way of the oil pump housing and secure.





11. Remove the generator lower mounting bolt (3).
12. Loosen the upper generator mounting bolt (6).
13. Pivot the generator out of the way and secure.
14. Remove the oil pan.
15. Remove the upper oil pan housing.





16. Mount the J 42065 to the crankshaft drive gear.
17. Use the J 42098 to remove the crankshaft drive gear bolt.





18. Remove the crankshaft drive gear.





19. Remove the six oil pump bolts.
20. Remove the three upper oil pan housing bolts that thread into the oil pump.
21. Remove the oil pump.
22. Remove the front main oil seal and collar from the oil pump.





23. Clean the oil pump sealing surfaces if the pump is to be reinstalled.
24. Clean the engine block (1) and the upper oil pan housing sealing surfaces.
25. Ensure all of the old sealant, gasket material and residual oil is removed.
26. Ensure the guide pins (2) are in place.

INSTALLATION PROCEDURE





1. Coat the pump side of the new oil pump gasket in the crosshatched areas shown in the illustration with a thin, even coating of anaerobic sealant GM P/N 1052942 or equivalent. (Note the tightening sequence).

Important: Do not cover and/or restrict the gasket openings with excess sealant.

2. Install the oil pump gasket.





3. Install the oil pump and align with the guide pins (2).





4. Apply thread sealant GM P/N 12346004, or equivalent, to the six oil pump bolts and install the bolts.

Notice: Refer to Fastener Notice in Service Precautions.

- Tighten the oil pump bolts, using the sequence shown, to 8 Nm (71 inch lbs).





5. Install the oil pump collar.
6. Install the front main oil seal. Coat the lip of the front main oil seal with a small amount of GM P/N 1052497 chassis grease or equivalent to aid in installation.
7. Use the J 35268-A to install the front main oil seal.
8. Ensure the front main oil seal if fully and evenly seated.
9. Install the crankshaft drive gear.
10. Install a new crankshaft drive gear bolt.
- Tighten the crankshaft drive gear bolt, while counterholding with J 42065, to 250 Nm (1184 ft lbs) + 45 degrees + 15 degrees.

11. Install the upper oil pan housing.
12. Install the oil pan.





13. Release and pivot the generator into place and install the generator lower mounting bolt (3).
- Tighten the generator lower (3) and upper bolts (6) to 40 Nm (30 ft lbs).

14. Position the A/C compressor and power steering pump bracket.
15. Install the A/C compressor and power steering pump bracket bolts.
- Tighten the A/C compressor and power steering pump bracket bolts to 40 Nm (30 ft lbs).

16. Install the A/C compressor.
17. Install the rear timing belt cover.
18. After installing and tightening to specifications the timing belt idler pulley for camshafts 3 and 4 in the previous procedure, re-tighten the six oil pump bolts.
- Tighten the six oil pump bolts to 9 Nm (80 inch lbs).

Important: The oil pump bolts must be re-tightened to the appropriate specifications AFTER the generator mounting bolts and the timing belt idler pulley for camshafts 3 and 4 have been tightened to specifications to allow for proper compression of the oil pump gasket.
The second design of the rear timing belt cover has a hole in it to access the oil pump bolt behind the cover.

19. Install the timing belt.
20. Install the front timing belt cover.
21. Install the intake air resonator.
22. Charge the A/C system.
23. Reconnect the negative battery cable and reprogram the applicable accessories.
24. Fill the cooling system.