Engine Front Cover
Engine Front Cover
Power Steering Pump
EGR Cooler
Radiator Hoses
Engine Front View
Heater Supply Tube
Coolant Pump and Thermostat
Engine Front Cover
Removal
NOTICE: Position a suitable protective material in front of the Charge Air Cooler (CAC) or damage to the CAC may occur.
1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
2. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal Service and Repair.
3. Remove the retaining nut for the power steering hose and tube.
4. NOTE: Raise the supply tube up to clear the Engine Coolant Temperature (ECT) sensor connector when positioning the power steering pump aside.
Remove the 3 bolts for the power steering pump. Position the power steering pump aside.
5. Loosen the clamp and disconnect the vertical EGR cooler coolant hose.
- Discard the vertical EGR cooler coolant hose clamp.
6. Remove the 2 retaining nuts for the vertical EGR cooler.
7. Remove the bolt and the EGR cooler coolant tube.
- Remove and discard the O-ring seal.
8. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector. Disconnect the coolant hose at the vertical EGR cooler.
9. Remove the nut and bolt for the vertical EGR cooler.
10. Remove the vertical EGR cooler stud.
- Remove and discard the gasket.
11. Remove the 5 bolts and the vertical EGR cooler assembly.
- Remove and discard the gasket.
12. Remove the retaining clip and disconnect the lower radiator hose.
13. Remove the retaining clip and the upper radiator hose.
14. Remove the 2 bolts and position aside the heater return tube.
- Remove and discard the O-ring seal.
15. Remove the 2 bolts and disconnect the EGR cooler coolant supply tube from the front cover.
- Remove and discard the O-ring seal and the clamp.
16. Remove the bolt and the accessory drive belt tensioner.
17. If equipped, remove the bolt and the A/C belt tensioner.
18. Remove the bolt and the accessory drive belt idler pulley.
19. Disconnect the ECT sensor electrical connector and wire retainer.
20. Remove the nut and 2 bolts for the heater supply tube and engine wiring harness.
21. NOTICE: Do not bend or flex the heater supply tube or damage to the tube may occur.
Position the heater supply tube as needed so that it will not interfere with the removal of the front cover. Secure the tube as needed.
- Remove and discard the O-ring seal.
22. NOTE: Remove the thermostat housing only if the front cover is being replaced.
Remove the 4 bolts, collar and the thermostat housing.
- Remove and discard the press-in-place gasket.
23. NOTE: Remove the coolant pump pulley only if the front cover is being replaced.
Remove the 4 bolts and the coolant pump pulley.
24. NOTE: Remove the coolant pump only if the front cover is being replaced.
Remove the 5 bolts and the coolant pump.
- Discard the O-ring seal.
25. NOTE: Mark the location of the 4 short bolts to aid in installing the oil pump housing.
Remove the 11 bolts and the oil pump housing.
- Remove and discard the press-in-place gasket.
26. NOTE: Mark the front of each drive rotor for correct reassembly orientation.
Remove the inner and outer oil pump drive rotors.
27. NOTE: Make the location of the front cover fasteners prior to removing them.
Remove the 10 bolts and the engine front cover.
28. NOTICE: Sealant is used where the upper and lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out while removing the front cover gasket.
NOTE: Engine removed for clarity.
Use a thin-blade scraper to cut the sealant where the upper and lower crankcase meet.
- Remove and discard the front cover gasket.
29. Remove the bolt and the EGR coolant adapter.
- Remove and discard the O-ring seal.
Installation
1. NOTE: Install a new O-ring seal.
Install the EGR coolant adapter and bolt.
- Tighten to 13 Nm (115 lb-in).
2. Apply a dime-sized bead of sealant at the front seam of the upper and lower crankcase.
3. NOTICE: Failure to use guide pins to position the front cover gasket may lead to oil in the coolant.
NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
Position the new front cover gasket on the engine and install guide pins.
4. Position the engine front cover and loosely install the 10 bolts.
5. NOTE: Install oil pump drive rotors with marks pointing outward.
Lubricate the inner drive rotor with clean engine oil and install onto the crankshaft. Lubricate the outer drive rotor with clean engine oil and mesh with the inner drive rotor.
6. Install a new press-in-place gasket, the oil pump housing and the 11 bolts.
- Tighten the 7 long bolts to 31 Nm (23 lb-ft).
- Tighten the 4 short bolts to 22 Nm (16 lb-ft).
7. Tighten the 10 engine front cover bolts.
- Tighten to 31 Nm (23 lb-ft).
8. NOTE: Install a new O-ring seal on the coolant pump.
If removed, install the coolant pump and the 5 bolts.
- Tighten to 31 Nm (23 lb-ft).
9. If removed, install the coolant pump pulley and the 4 bolts.
- Tighten to 31 Nm (23 lb-ft).
10. If removed, install a new press-in-place gasket. Install the thermostat housing, collar and 4 bolts.
- Tighten to 13 Nm (115 lb-in).
11. NOTICE: Do not bend or flex the heater supply tube or damage to the tube may occur.
NOTE: Install a new O-ring seal.
Position back the heater supply tube.
12. Install the nut and 2 bolts for the heater supply tube and engine wiring harness.
- Tighten to 13 Nm (115 lb-in).
13. Connect the ECT sensor electrical connector and wire retainer.
14. Install the accessory drive belt idler pulley and bolt.
- Tighten to 47 Nm (35 lb-ft).
15. If equipped, install the A/C belt tensioner and bolt.
- Tighten to 47 Nm (35 lb-ft).
16. Install the accessory drive belt tensioner and bolt.
- Tighten to 47 Nm (35 lb-ft).
17. NOTE: Install a new O-ring seal on the tube.
NOTE: Hand start both bolts prior to tightening the bolts.
Position back the EGR cooler coolant supply tube and install the 2 bolts.
- Tighten to 13 Nm (115 lb-in).
18. NOTE: Install a new O-ring seal.
Position back the heater return tube and install the 2 bolts.
- Tighten to 13 Nm (115 lb-in).
19. Install the upper radiator hose and retaining clip.
20. Position back the lower radiator hose and install the retaining clip.
21. NOTE: Install a new horizontal EGR cooler gasket prior to installing the vertical EGR cooler.
Position the vertical EGR cooler assembly and loosely install the 5 bolts.
22. Install a new vertical EGR cooler gasket and the stud.
- Tighten to 17 Nm (150 lb-in).
23. Install the nut and bolt for the vertical EGR cooler.
- Tighten to 31 Nm (23 lb-ft).
24. Connect the EGRT sensor electrical connector. Connect the coolant hose to the vertical EGR cooler.
25. NOTE: Install a new O-ring seal.
Install the vertical EGR cooler tube and bolt.
- Tighten to 10 Nm (89 lb-in).
26. NOTICE: Do not bend or twist the EGR cooler bellows or damage to the EGR cooler may occur.
NOTE: Inspect the corrugation of the vertical EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.
Install the 2 nuts for the vertical EGR cooler.
- Tighten to 31 Nm (23 lb-ft).
27. NOTICE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.
NOTE: Install a new clamp on the vertical EGR cooler coolant hose.
Connect the vertical EGR cooler coolant hose and tighten the clamp.
- Tighten to 4 Nm (35 lb-in).
28. Tighten the 5 EGR cooler bolts.
- Tighten the M8 bolts to 31 Nm (23 lb-ft).
- Tighten the M10 bolt to 62 Nm (46 lb-ft).
29. Install the 3 bolts for the power steering pump.
- Tighten to 25 Nm (18 lb-ft).
30. Install the retaining nut for the power steering hose and tube.
- Tighten to 25 Nm (18 lb-ft).
31. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal Service and Repair.
32. Install the ACL outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.