Timing Cover: Service and Repair

Front Cover Components:

Fig. 22 Injection pump & cam gear alignment:

SPECIAL TOOLS REQUIRED (or equivalents)
^ J-22102, Front cover seal installer.
^ J-33O42, Timing fixture (if a new cover is to be installed).

REMOVE OR DISCONNECT
1. Drain the cooling system and remove the water pump.
2. Rotate the engine until the timing marks on the pump gear and camshaft gear are aligned. Scribe a mark aligning the injection pump flange and front cover.
3. Torsional damper.
4. Four front cover to oil pan bolts.
5. Two fuel return line clips.
6. Injection pump gear and pump retaining nuts at the front cover.
7. Baffle.
8. Front cover bolts and front cover.
9. Front crankshaft seal, pry out with a screwdriver.
10. Clean Sealing surfaces on front cover and oil pan.
11. Inspect front cover for cracks or damage to sealing surfaces.

INSTALL OR CONNECT
1. New front crankshaft seal to the front cover using J-22102.
^ Apply a 2 mm (3/32 in) bead of anaerobic sealant GM P/N 1052357 or equivalent to the front cover sealing area.
^ Apply a 5 mm (3/16 in) bead of RTV sealant to the front cover sealing surface that mates against the oil pan.

2. Front cover to the engine. Install the attaching bolts and tighten cover to block bolts to 45 Nm (33 ft lbs) and oil pan to cover bolts to 10 Nm (84 in lbs).
3. Baffle and tighten bolts and nut to 45 Nm (33 ft lbs).
4. Align the scribe marks on the front cover and injection pump.
5. If a new front cover is installed, mark TDC on front housing as follows:
a. Set the engine so that number 1 cylinder is at TDC (firing).
b. Install J-33042 in the injection pump location. Do not use the gasket.
c. The slot in the injection pump gear should be in the vertical 6 o'clock position. If not, remove J-33O42 and rotate the engine crankshaft 360°. The timing marks on the gears should be aligned.
d. Fasten J-33042 to the gear and tighten.
e. Install one 10 mm nut to the upper housing stud to hold the tool flange and finger tighten.
f. Tighten the large bolt (18 mm head) clockwise (looking at the front of the engine) to 48 Nm (35 ft lbs).
g. Tighten the 10 mm nut. Check that the crankshaft has not rotated and that the tools did not bind.
h. Strike the scribe tool with a mallet to mark TDC on the front housing and remove J-33042.

6. Injection pump nuts and tighten to 42 Nm (31 ft lbs).
7. Injection pump gear and bolts. Align the timing marks and tighten gear bolts to 23 Nm (17 ft lbs).
8. Measure the clearance between injection pump gear and baffle. It is necessary to maintain a minimum of 1.0 mm (0.040 in) between the gear and baffle, or noise may result.
9. Fuel return line bolts.
10. Torsional damper.
11. Water pump and fill the cooling system with the proper quantity and grade of coolant.