Gasket - Front Cover

GASKET - FRONT COVER
Service repair no -12.65.04


Remove
1. Remove oil pick-up strainer.
2. Remove front cover oil seal.
3. Drain cooling system.





4. Remove bolt securing auxiliary belt jockey pulley and remove pulley.
5. Remove 3 bolts securing water pump pulley and remove pulley.





6. Release clip and disconnect bottom hose from radiator.
7. Release clip and disconnect top hose from radiator.





8. Release clip and disconnect coolant hose from water pump.
9. Release thermostat housing from radiator cowl and move hoses clear of front cover.





10. Position cloth to collect spillage and loosen both gearbox fluid cooler pipe unions and engine oil cooler inlet pipe union.





11. Remove 2 clips securing radiator cowl and remove cowl.





12. Remove engine oil filter.
13. Disconnect Lucar from oil pressure switch.
14. Disconnect multiplug from CMP sensor.





15. Remove bolt securing engine oil cooler return pipe to alternator bracket.





16. Loosen unions and disconnect oil cooler feed and return pipes from front cover, remove and discard O-rings.

CAUTION: Plug the connections.

17. Remove 9 bolts securing front gear cover and remove cover. Remove and discard gasket.


Refit
18. Clean mating faces of front cover and cylinder block. Clean dowels and dowel holes.
19. Fit new gasket onto dowels in cylinder block.





20. Fit front cover to cylinder block and tighten bolts in sequence shown to 22 Nm (16 ft. lbs.). Ensure CMP sensor multiplug bracket is secured by bolt
21. Fit new O-rings to oil cooler pipes, connect pipes to front cover and tighten unions to 15 Nm (11 ft. lbs.).
22. Fit bolt securing oil cooler return pipe to alternator mounting bracket.
23. Connect Lucar to oil pressure switch.
24. Connect multiplug to CMP sensor.
25. Ensure oil filter seal and mating face on front cover is clean.
26. Lubricate seal with clean engine oil and fit engine oil filter.
27. Fit radiator cowl and secure with clips.
28. Fit oil cooler pipes into recesses in radiator cowl and tighten pipe unions to 30 Nm (22 ft. lbs.).
29. Fit thermostat housing to radiator cowl.
30. Connect bottom coolant hose to radiator and secure with clip.
31. Connect hose to water pump and secure with clip.
32. Connect top hose to radiator and secure with clip.
33. Ensure mating faces of water pump pulley and drive flange are clean, fit pulley and tighten bolts to 22 Nm (16 ft. lbs.).
34. Fit auxiliary belt jockey pulley and tighten bolt to 50 Nm (37 ft. lbs.).
35. Fit front cover oil seal.
36. Fit oil pick-up strainer.
37. Refill cooling system.