Timing Cover: Service and Repair

Engine Front Cover Replacement

Removal Procedure




1. Drain the engine cooling system.
2. Drain the charge air cooling system.
3. Remove the supercharger assembly.




4. Remove the water outlet housing.
5. Remove the air conditioning, power steering, and water pump drive belt.
6. Remove the air conditioning, power steering, and water pump drive belt tensioner.
7. Remove the air conditioning, power steering, and water pump drive belt idler pulley.
8. Remove the supercharger drive belt tensioner.
9. Remove the supercharger drive belt idler pulley that mounts to the front cover.
10. Remove the front engine compartment sight shield.
11. Remove the electric cooling fan assembly.
12. Remove the charge air cooling coolant pump.
13. Remove the charge air cooler radiator inlet and outlet hoses.




14. Remove the heater hose from the thermostat housing.
15. Remove the radiator hose from the thermostat housing.
16. Remove the generator drive belt.
17. Remove the generator drive belt tensioner.
18. Remove the water pump pulley.




19. Remove the crankshaft balancer (2).
20. Ensure that you do not lose the oil pump drive to crankshaft balancer friction washer (3) that may come off with the balancer.




21. Remove the engine front cover bolts (3).
22. Remove the engine front cover (2).
23. Remove and discard the engine front cover gasket (1).
24. If replacing the front cover, remove the water pump, thermostat, and front cover fitting.
25. Clean and inspect the front cover.
26. Clean and inspect the front cover mating surface.

Installation Procedure




1. Ensure that the oil pump drive to crankshaft balancer friction washer is in place.




2. If previously removed, install the water pump, the thermostat, and the front cover fitting.
3. Place a small amount of sealant at the split line of the upper and lower crankcases (1). Refer to Sealers, Adhesives, and Lubricants for the correct part number.




4. Place the NEW engine front cover gasket over the crankcase dowel pins.




5. Place a small amount of sealant at the engine front cover gasket pad area located on top of the split line of the upper and lower crankcases (1). Refer to Sealers, Adhesives, and Lubricants for the correct part number.




6. Place the engine front cover (2) in position on the crankcase.
7. Apply the thread locking compound to the threads of the engine front cover bolts (3). Refer to Sealers, Adhesives, and Lubricants for the correct part number.





Notice: Refer to Fastener Notice.

8. Tighten the engine front cover bolts in the sequence shown.

Tighten the engine front cover bolts in proper sequence to 15 N.m (11 lb ft).




9. Install the crankshaft balancer (2).




10. Install the water pump pulley.
11. Install the generator drive belt tensioner.
12. Install the generator drive belt.
13. Install the radiator hose to the thermostat housing.
14. Install the heater hose to the thermostat housing.
15. Install the charge air cooler radiator inlet and outlet hoses.
16. Install the charge air cooling coolant pump.
17. Install the electric cooling fan assembly.
18. Install the front engine compartment sight shield.
19. Install the supercharger drive belt idler pulley.




20. Install the supercharger drive belt tensioner.
21. Install the air conditioning, power steering, and water pump drive belt idler pulley.
22. Install the air conditioning, power steering, and water pump drive belt tensioner.
23. Install the air conditioning, power steering, and water pump drive belt.
24. Install the water outlet housing.




25. Install the supercharger assembly.
26. Fill the charge air cooling system with coolant.
27. Fill the engine cooling system with coolant.
28. Check the front cover, the engine cooling system, and the charge air cooling system for leaks.