Timing Cover: Service and Repair

Engine Front Cover Replacement

Special Tools

J 41476 Front and Rear Cover Alignment Tool (at crankshaft seal area)

Removal Procedure




1. Remove the generator. Refer to Generator Replacement (LS4) (Generator Replacement)Generator Replacement (RPOs LZE/LZ4/LZ8) (Generator Replacement).
2. Remove the power steering pump. Refer to Power Steering Pump Replacement (LZ4/LZE/LZ9) (Service and Repair)Power Steering Pump Replacement (LS4) (Service and Repair).
3. Remove the coolant pump manifold. Refer to Coolant Pump Manifold Replacement (Service and Repair).
4. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (Service and Repair).
5. Remove the belt tensioner bolt and reposition the tensioner (which blocks the front cover bolt).
6. Remove the oil pan-to-front cover bolts.
7. Remove the front cover bolts (1).
8. Remove the front cover (2) and gasket (3).
9. Discard the front cover gasket.




10. Remove the oil seal (4).
11. Remove the bolt (1) and camshaft position (CMP) sensor (2).
12. Remove the O-ring (3) from the sensor, as required.

Installation Procedure

Note:
* Do not reuse the crankshaft oil seal or front cover gasket.
* Do not apply any type of sealant to the front cover gasket (unless specified).
* The special tool in this procedure is used to properly center the front crankshaft front oil seal.

- All gasket surfaces should be free of oil or other foreign material during assembly.
- The crankshaft front oil seal MUST be centered in relation to the crankshaft.
- An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks.





1. Install the front cover gasket (3), front cover (2), and bolts (1).
2. Tighten the cover bolts finger tight. Do not overtighten.





Caution: Refer to Fastener Caution (Fastener Caution).

Note: Start the tool-to-front cover bolts. Do not tighten the bolts at this time.

3. Install the J 41480 .

Tighten the tool-to-engine block bolts to 25 Nm (18 lb ft).





Note: Align the tapered legs of the tool with the machined alignment surfaces on the front cover.

4. Install the J 41476 .
5. Install the crankshaft balancer bolt.

1. Tighten the crankshaft balancer bolt by hand until snug. Do not overtighten.
2. Tighten the J 41480 .
3. Tighten the engine front cover bolts to 25 Nm (18 lb ft).

6. Remove the tools.




7. Measure the oil pan surface flatness, front cover-to-engine block.

1. Place a straight edge across the engine block and front cover oil pan sealing surfaces.
Avoid contact with the portion of the gasket that protrudes into the oil pan surface.
2. Insert a feeler gage between the front cover and the straight edge tool. The cover must be flush with the oil pan surface, or no greater than 0.5 mm (0.02 in) below flush.

8. If the front cover-to-engine block oil pan surface alignment is not within specifications, repeat the cover alignment procedure.
9. If the correct front cover-to-engine block alignment cannot be obtained, replace the front cover.




10. Inspect the camshaft position (CMP) sensor O-ring seal (3) for cuts or damage. If the seal is not cut or damaged, it may be used again.
11. Lubricate the O-ring seal with clean engine oil.
12. Install the O-ring seal onto the sensor (2).
13. Install the sensor to the cover.
14. Install the bolt (1).

Tighten the bolt to 12 Nm (106 lb in).

15. Install the coolant pump manifold. Refer to Coolant Pump Manifold Replacement (Service and Repair).
16. Inspect the CMP sensor O-ring seal (3) for cuts or damage. If the seal is not cut or damaged, it may be reused.
17. Lubricate the O-ring seal with clean engine oil.
18. Install the O-ring seal (3) onto the CMP sensor.
19. Install the CMP sensor (2) and bolt (1) from the front cover.

Tighten the bolt to 12 Nm (106 lb in).

20. Position the belt tensioner and install the bolt.

Tighten the bolt to 50 Nm (37 lb ft).

21. Install the power steering pump. Refer to Power Steering Pump Replacement (LZ4/LZE/LZ9) (Service and Repair)Power Steering Pump Replacement (LS4) (Service and Repair).
22. Install the generator. Refer to Generator Replacement (LS4) (Generator Replacement)Generator Replacement (RPOs LZE/LZ4/LZ8) (Generator Replacement).