Engine Front Cover

Engine Front Cover













Removal

1. Remove the upper oil pan. For additional information, refer to Oil Pan - Upper Oil Pan - Upper.

2. Remove the cooling module, cooling fan stator and cooling fan. For additional information, refer to Engine Cooling - Diesel Engine Cooling Module.

3. Remove the accessory drive belt , accessory drive belt tensioner and cooling fan drive assembly. For additional information, refer to Accessory Drive Service and Repair, Accessory Drive Belt Tensioner, and Service and Repair.

4. Remove the A/C compressor. For additional information, refer to Climate Control Service and Repair.

5. Remove the vacuum pump. For additional information, refer to Power Brake Actuation Service and Repair.

6. Disconnect the Camshaft Position (CMP) sensor electrical connector and the 3 wire retainers.





7. Disconnect the power steering tube from the retainer. Remove the 2 bolts for the engine wire harness.





8. Remove the clip and disconnect the lower radiator hose.





9. Disconnect the engine wire harness retainer from the power steering pump bracket and position engine wire harness aside.





10. Remove the clip and disconnect the engine fill hose from the degas bottle.





11. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal Service and Repair.

12. NOTICE: Use care when removing the engine front cover not to scratch the crankshaft sealing surface.

NOTE: Make the location of the front cover bolts prior to removing them.

Remove the 14 bolts and the engine front cover.

- Discard the engine front cover.

- Clean and inspect the sealing surfaces.

Installation

1. NOTICE: Failure to properly align the engine front cover to the oil pan rail may result in engine damage.

NOTICE: Use care when installing the engine front cover not to scratch the crankshaft sealing surface.

NOTE: Use the Gauge Bar to align the bottom of the engine front cover to the oil pan rail prior to torquing the engine front cover.

Using new gaskets, install the new engine front cover and 14 bolts.

- Support the oil pump gerotor assembly in the engine front cover bore.

- Position the engine front cover assembly over the crankshaft without contacting the front sealing surface.

- Align the oil pump gerotor assembly with the crankshaft drive flats.

- Align the engine front cover assembly locating pin.

- Slide the front cover assembly over the crankshaft post to the cylinder block sealing surface.

- Hand start bolt number 1 and 2.

- Using the Gauge Bar, align the bottom of the engine front cover to the oil pan rail.

- Install the remaining engine front cover bolts. Tighten in the sequence shown.

- Tighten to 24 Nm (18 lb-ft).





2. As a post-check, using the Gauge Bar and Feeler Gauge Set, verify alignment of the engine front cover to the oil pan rail is within 0.25 mm (0.009 in).
- If the engine front cover alignment is not with specification, loosen the bolts and repeat step 1.

3. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal Service and Repair.

4. Connect the engine fill hose to the degas bottle and install the clip.





5. Position back the engine wire harness and connect the engine wire harness retainer to the power steering pump bracket.





6. Connect the lower radiator hose and install the clip





7. Install the 2 bolts for the engine wire harness. Connect the power steering tube to the retainer.
- Tighten to 10 Nm (89 lb-in).





8. Connect the CMP sensor electrical connector and the 3 wire retainers.





9. Install the vacuum pump. For additional information, refer to Power Brake Actuation Service and Repair.

10. Install the A/C compressor. For additional information, refer to Climate Control Service and Repair.

11. Install the cooling fan drive assembly, accessory drive belt tensioner and accessory drive belt. For additional information, refer to Accessory Drive Service and Repair, Accessory Drive Belt Tensioner, and Service and Repair.

12. Install the cooling fan, cooling fan stator and cooling module. For additional information, refer to Engine Cooling - Diesel Engine Cooling Fan.

13. Install the upper oil pan. For additional information, refer to Oil Pan - Upper Oil Pan - Upper.