SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET1999PICKUP K1500, 5.7 RREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 663 (ENGINE MECHANICAL - 3.8L (ON-VEHICLE))REPAIR INSTRUCTIONSENGINE FRONT COVER REPLACEMENTINSTALLATION PROCEDURE
1999 Chevrolet Pickup K1500, 5.7 R

Installation Procedure

1999 Chevrolet Pickup K1500, 5.7 RSECTION Installation Procedure
WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. If replacing the engine front cover, install the camshaft position sensor.
    NOTE: Refer to FASTENER NOTICE .
  2. Install the camshaft position bolt.

    Tighten 

    Tighten the bolts to 10 N.m (89 lb in).

    Fig 1: Camshaft Position Sensor
    G01703274Courtesy of GENERAL MOTORS CORP.
  3. 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 .
    Fig 2: Oil Pump Cover & Gear Set
    G01703275Courtesy of GENERAL MOTORS CORP.
  4. If replacing the engine front cover, install the water pump gasket and the water pump to the front cover.
  5. Install the water pump bolts to the water pump.

    Tighten 

    • Tighten the long water pump bolts to 34 N.m (25 lb ft).
    • Tighten the short water pump bolts to 22 N.m (16 lb ft).
      Fig 3: Water Pump & Bolts
      G01703276Courtesy of GENERAL MOTORS CORP.
  6. If replacing the engine front cover, install the pressure relief valve, the oil filter adapter gasket and the oil filter adapter to the front cover.
  7. Install the oil filter adapter bolts to the oil filter adapter.

    Tighten 

    Tighten the bolts to 30 N.m (22 lb ft).

    Fig 4: Oil Filter Adapter
    G01703277Courtesy of GENERAL MOTORS CORP.
  8. Install the new engine front cover gasket. Ensure that the sealing surfaces are not damaged.
  9. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolt threads.
    Fig 5: Engine Front Cover Gasket
    G01703278Courtesy of GENERAL MOTORS CORP.
  10. Align the cogs on the crankshaft sprocket with the cogs on the oil pump gear set in the engine front cover.
  11. Install the engine front cover to the engine.
    Fig 6: Engine Front Cover
    G01703279Courtesy of GENERAL MOTORS CORP.
  12. Install the engine front cover bolts (1-7).

    Tighten 

    Tighten the bolts to 34 N.m (25 lb ft).

    Fig 7: Engine Front Cover Bolts
    G01703280Courtesy of GENERAL MOTORS CORP.
  13. Install the crankshaft position sensor.
  14. Install the crankshaft position sensor studs.

    Tighten 

    Tighten the studs to 30 N.m (22 lb ft).

    Fig 8: Crankshaft Position Sensor
    G01703281Courtesy of GENERAL MOTORS CORP.
  15. Install the new engine front cover seal using J 35354. 
  16. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover.
  17. Remove the J 35354. 
  18. Install the oil pan-to-engine front cover bolts.

    Tighten 

    Tighten the bolts to 14 N.m (125 lb in).

  19. Install the oil level sensor

    Tighten 

    Tighten the sensor to 20 N.m (15 lb ft).

  20. Connect the oil level sensor electrical connector.
  21. Install the engine mount bracket. Refer to Engine Mount and Bracket Replacement .
    Fig 9: Installing Crankshaft Front Oil Seal
    G01703282Courtesy of GENERAL MOTORS CORP.
  22. Install the oil filter.
    Fig 10: Oil Filter
    G01703283Courtesy of GENERAL MOTORS CORP.
  23. Install the crankshaft position sensor shield.
  24. Connect the electrical connectors to the following:
    • Oil pressure sensor
    • Crankshaft position (CKP) sensor
    • Camshaft position (CMP) sensor
  25. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  26. Lower the vehicle.
  27. Remove the engine support fixture.
  28. Install the radiator outlet hose to the water pump. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.1 L) or RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) .
  29. Install the water pump pulley.
  30. Install the water pump pulley bolts.

    Tighten 

    Tighten the bolts to 13 N.m (116 lb in).

  31. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) .
  32. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
  33. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  34. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  35. Inspect for leaks.
  36. Perform the CKP system variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR SYSTEM VARIATION LEARN PROCEDURE .
    Fig 11: Crankshaft Position Sensor Shield
    G01703284Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.