Timing Cover: Service and Repair

Engine Front Cover

Material:

Removal

All vehicles
1. Remove the intake manifold.
2. Remove the nut and position the fuel line retaining bracket aside.





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

Remove the 2 stud bolts and the thermostat housing.
^ Remove and discard the O-ring seal.





4. NOTE: Only one shown, others similar.

Remove the bolts and the accessory drive idler pulleys.





5. NOTE: The nut behind the pulley is accessed through one of the holes in the pulley.

Remove the nuts and the coolant hose shield.





6. Loosen the clamp and disconnect the engine coolant fill hose.





7. Remove the power steering pump upper mounting bolts.





8. Remove the LH fan stator stand-off.





9. NOTE: The front bolt will remain in the power steering pump.

Remove the power steering pump bolts and position aside.





10. Disconnect the lower radiator hose.





Vehicle with single generator
11. Remove the bolts and the accessory drive belt tensioner.





All vehicles

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

Remove the 4 bolts and the coolant pump pulley.





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

Remove the 4 bolts and the coolant pump.
^ Remove and discard the O-ring seal.





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

All vehicles
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.
^ Tighten to 24 Nm (18 ft. lbs).





6. Install the oil pump.

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

If removed, install the coolant pump and bolts.
^ Tighten to 23 Nm (17 ft. lbs).





8. If removed, install the coolant pump pulley and bolts.
^ Tighten to 31 Nm (23 ft. lbs).





Vehicles with single generator
9. Install the accessory drive belt tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs).





All vehicles
10. Install the lower radiator coolant hose.





11. Position the power steering pump and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs).





12. Install the LH fan stator stand-off.
^ Tighten to 47 Nm (35 ft. lbs).





13. Install the power steering pump upper mounting bolts.
^ Tighten to 25 Nm (18 ft. lbs).





14. Connect the engine coolant fill hose and tighten the clamp.





15. NOTE: The nut behind the pulley is accessed through one of the holes in the pulley.

Position the coolant hose shield and install the nuts.
^ Tighten to 6 Nm (53 inch lbs).





16. Install the accessory drive idler pulleys and bolts, as needed.
^ Tighten to 47 Nm (35 ft. lbs).





17. NOTE: Install a new O-ring seal.

If removed, install the thermostat housing and stud bolts.
^ Tighten to 23 Nm (17 ft. lbs).





18. Position back the fuel line retaining bracket and install the nut.





19. Install the intake manifold.