Engine Front Cover

Engine Front Cover





Material

Removal
1. Remove the intake manifold.





2. Disconnect the exhaust pressure tube at the exhaust.





3. Remove the nuts and the exhaust pressure bracket assembly.





4. NOTE: Remove the thermostat housing only if a new front cover is being installed.

Remove the stud bolts and the thermostat housing.
^ Remove and discard the O-ring.





5. Disconnect the engine coolant fill hose.





6. Disconnect the lower radiator hose.





7. Remove the stator stand-off bolt.





8. NOTE: Upper bolts shown, lower bolts similar.

Remove the four bolts and position aside the power steering pump.





9. Remove the bolts and the accessory drive belt tensioner.





10. NOTE: Remove the accessory drive pulleys, only if a new front cover is being installed.

NOTE: Only one shown, others similar.

Remove the bolts and the accessory drive idler pulleys.





11. NOTE: Remove the coolant pump pulley only if a new front cover is being installed.

Remove the coolant pump pulley.





12. NOTE: Remove the coolant pump only if a new front cover is being installed.

Remove the bolts and the coolant pump.
^ Remove and discard the O-ring.





13. Remove the nut and the battery cable bracket.
14. Remove the oil pump.





15. Remove the bolts and the front cover.

16. CAUTION: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the front cover gasket.

Use a thin blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
^ Clean and inspect the sealing surfaces.

Installation





1. If removed, install the front cover crankcase dowels into the cylinder block.





2. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.

Install the guide studs.





3. Apply a bead of sealant at the seam where the crankcase and the lower crankcase meet.





4. Install a new engine front cover gasket.





5. Install the engine front cover and bolts.
6. Install the oil pump.





7. Install the battery cable bracket and nut.





8. NOTE: Install a new O-ring on the coolant pump pulley.

If removed, install the coolant pump and bolts.





9. If removed, install the coolant pump pulley and bolts.





10. Install the accessory drive idler pulleys and bolts.





11. Install the accessory drive belt tensioner and bolts.





12. Position back the power steering pump and install the bolts.





13. Install the stator stand-off bolt.





14. Connect the lower radiator coolant hose.





15. Connect the engine coolant hose.





16. NOTE: Install a new O-ring.

If removed, install the thermostat housing and stud bolts.





17. Install the exhaust pressure bracket assembly and retaining nuts.





18. Connect the exhaust pressure tube fitting at the exhaust manifold.
19. Install the intake manifold.