Timing Cover: Service and Repair

FRONT COVER AND OIL PUMP ASSEMBLY REPLACEMENT

TOOLS REQUIRED
- J38122A Crankshaft Pulley Holder
- J44811 Accessory Belt Tensioner Unloader
- J45122 Engine Support Adapter
- SA9105E Engine Three-Bar Fixture

REMOVAL

CAUTION: ENSURE THAT THE VEHICLE IS SECURELY SUPPORTED BEFORE LIFTING ON A HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FROM VEHICLE ON OPPOSITE END FROM WHICH COMPONENTS BEING REMOVED. ENSURE THAT THE HOIST DOES NOT CONTACT FUEL LINES OR BRAKE LINES.





1. Disconnect negative battery cable.
2. Disconnect Intake Air Temperature (IAT) sensor connector.
3. Loosen clamp at air cleaner assembly.
4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
5. Loosen clamp at throttle body assembly.
6. Disconnect PVC fresh air vent hose at cam cover.
7. Remove outlet resonator/duct assembly.





8. Install Engine Three-Bar Fixture SA9105E set up for SUV application. AISLE use Engine Support Adapter J45122.





9. Remove right hand mount.
10. Remove right hand engine mount bracket.
11. Jack vehicle or raise on hoist.
12. Remove right wheel and splash shield.





13. Install Accessory Belt Tensioner Unloader J44811 tool.





14. Remove accessory drive belt.

IMPORTANT: To remove tensioner bolt, an access hole has been provided through the inner and outer engine rail.

15. Remove tensioner bolt.
16. Remove tensioner assembly.





17. Install Crankshaft Pulley Holder J38122A.





18. Remove crankshaft balancer pulley bolt and pulley. Discard pulley bolt.





NOTICE: The crankshaft balancer pulley bolt head and washer assembly prevents oil leakage at center of pulley. Do not damage sealing surfaces. If pulley cannot be removed by pulling with hand, use a three-jaw puller.

NOTICE: To avoid damage to the front cover assembly, do not pry against cover.

19. Remove front cover assembly bolts.
20. Remove lower water pump assembly bolt.
21. Remove front cover assembly and gasket.

INSTALLATION

IMPORTANT: A new oil seal can be installed either in or out of the vehicle.

1. Install new front cover gasket.
2. Install front cover assembly.
3. Install front cover assembly bolts and lower water pump bolt.

Tighten
Front Cover-to-Block Bolts - L61: 25 N.m (18 ft. lbs.)
Tighten
Water Pump Bolts - L61: 25 N.m (18 ft. lbs.)





4. Lubricate front seal and sealing surface of pulley with clean motor oil.
5. Installer balancer pulley onto crankshaft indexing keyway. Use care to properly align the flats on balancer pulley with flats on oil pump drive in front cover assembly.
6. Install crankshaft damper pulley.
7. Install new crankshaft balancer pulley bolt with washer assembly.





8. Install J38122 Crankshaft Pulley Holder.

Tighten
Crankshaft Pulley Bolt - L61: 100 N.m (74 ft. lbs.) +75 degrees





9. Install drive belt tensioner assembly.

Tighten
Drive Belt Tensioner Bolt - L61: 45 N.m (33 ft. lbs.)





10. Route belt around alternator and A/C compressor. Install J39914 Accessory Drive Belt tool onto tensioner and unload spring tension from tensioner while positioning belt.
11. Release tensioner and remove tool.
12. Install right engine inner splash shield.
13. Install right wheel and hand tighten wheel nuts.
14. Lower vehicle.
15. Tighten tire nuts.

Tighten
Wheel Nuts: 140 N.m (100 ft. lbs.)





16. Install right hand engine bracket and bolts to engine.

Tighten
Engine Mount Bracket-to-Engine Bolts L61: 110 N.m (81 ft. lbs.)





17. Install right hand engine mount over body side rail studs.
18. Install right hand engine mount nuts.

Tighten
Engine Mount Bracket-to-Body Nuts L61: 10 N.m (81 ft. lbs.)

19. Install right hand engine mount bolts to engine mount bracket.

Tighten
Engine Mount-to-Engine Mount Bracket Bolts L61: 50 N.m (37 ft. lbs.)





IMPORTANT: When starting vehicle, check for excessive idle shake. Powertrain re-balance may be required.

20. Remove SA9105E Engine Three Bar Fixture.
21. Position outlet resonator/duct assembly into position.
22. (Connect PCV fresh air vent hose assembly.
23. Tighten clamp at throttle body assembly.
24. Position outlet resonator/duct assembly up with support bracket and install push-pin.
25. Tighten clamp at air cleaner assembly.
26. Connect Intake Air Temperature (IAT) sensor connector.
27. Connect negative battery cable.

Tighten
Battery Terminal Bolt: 17 N.m (13 ft. lbs.)+75 degrees