Front Cover and Oil Pump Assembly Replacement

FRONT COVER AND OIL PUMP ASSEMBLY REPLACEMENT

- TOOLS REQUIRED
- J38122A Crankshaft Pulley Holder
- J43405 Engine Support Fixture Adapter
- SA9105E Engine Support Fixture (3-Bar)

REMOVAL





1. Disconnect negative battery cable.
2. Remove air cleaner assembly.

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





3. Jack vehicle or raise on a hoist.
4. Drain engine oil.





5. Remove right wheel and splash shield.





6. Remove engine accessory drive belt.

NOTICE: The crankshaft damper pulley bolt head and washer assembly prevents oil leakage at the center of the pulley. Do not damage sealing surfaces.





7. Remove crankshaft damper pulley bolt using Crankshaft Pulley Holder J38122A.

IMPORTANT: If pulley cannot be removed by pulling by hand' use a three jaw puller. Do not pry against cover.





8. Remove belt tensioner.





9. Install Engine Support Fixture (3-Bar) SA9105E and Engine Support Fixture Adapter J43405.
10. Remove right engine mount.





11. Remove front cover bolts.

IMPORTANT: The 13 mm bolt under the water pump cover must also be removed.

12. Remove front cover assembly and front cover gasket.

INSTALLATION

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

1. Jack vehicle or raise on a hoist.





2. Install new front cover gasket and cover assembly.
3. Install front cover bolts.
Torque:
Front Cover-to-Block Bolts: 25 Nm (18 ft. lbs.)





4. Install right engine mount.
5. Remove Engine Support Fixture SA9150E and Engine Support Fixture Adapter J-43405.
6. Install drive belt tensioner.
Torque:
Drive Belt Tensioner Bolt: 50 Nm (37 ft. lbs.)





7. Install crankshaft damper pulley.
7.1. Lubricate front seal and sealing surface of damper pulley with clean motor oil.
7.2. Install damper onto crankshaft indexing keyway, use care to properly align the flats on damper with flats on oil pump drive.





7.3. Install crankshaft damper pulley bolt and washer using Pulley Holding Tool J-38122A while tightening.
Torque:
Crankshaft Damper Pulley Bolt: 100 Nm (74 ft. lbs.) + 75°





8. Install engine accessory drive belt.





9. Install right wheel and splash shield.





10. Add engine oil to specifications.





11. Install air cleaner assembly.
12. Connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 Nm (13 ft. lbs.)