Timing Cover: Service and Repair

Engine Front Cover Replacement

Tools Required

J 41476 Front and Rear Cover Alignment (at crankshaft seal area)

Removal Procedure




1. Remove the generator.
2. Remove the power steering pump.
3. Remove the coolant pump manifold.
4. Remove the crankshaft balancer.
5. Remove the belt tensioner bolt and reposition the tensioner (which blocks the front cover bolt).
6. Remove the oil pan-to-front cover bolts.
7. Remove the front cover bolts (501).
8. Remove the front cover (502) and gasket (503).
9. Discard the front cover gasket.




10. Remove the oil seal (140), if necessary.
11. Remove the camshaft position (CMP) sensor bolt (705) and sensor (703), if necessary.
12. Remove the O-ring seal (704) from the sensor, if necessary.
13. Clean and inspect the engine front cover. Refer to Engine Front Cover Cleaning and Inspection (First Design) Engine Front Cover Cleaning and Inspection (Second Design).

Installation Procedure

Important:
* Do not reuse the crankshaft oil seal or front cover gasket.

* Do not apply any type of sealant to the front cover gasket (unless specified).

* The special tool in this procedure is used to properly center the front crankshaft front oil seal.

- All gasket surfaces should be free of oil or other foreign material during assembly.

- The crankshaft front oil seal MUST be centered in relation to the crankshaft.

- An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks.




1. Apply a 5 mm (0.20 in) bead of sealant or equivalent 20 mm (0.80 in) long to the oil pan to engine block junction. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
2. Install the front cover gasket (503) and cover (502).
3. Install the front cover bolts until snug (502). Do not overtighten.
4. Install the oil pan-to-front cover bolts until snug. Do not over tighten.




5. Install the J 41476 to the front cover.
6. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover.

Notice: Refer to Fastener Notice.

7. Install the crankshaft balancer bolt until snug. Do not overtighten.

* Tighten the oil pan to front cover bolts to 25 N.m (18 lb ft).
* Tighten the engine front cover bolts to 25 N.m (18 lb ft).

8. Remove the J 41476.




9. Install a NEW crankshaft front oil seal (140).
10. Install the coolant pump manifold.
11. Inspect the CMP sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused.
12. Lubricate the O-ring seal with clean engine oil.
13. Install the O-ring seal (704) onto the CMP sensor.
14. Install the CMP sensor (703) and bolt (705) from the front cover.

Tighten the bolt to 12 N.m (106 lb in).

15. Position the belt tensioner and install the bolt.

Tighten the bolt to 50 N.m (37 lb ft).

16. Install the power steering pump.
17. Install the generator.