Timing Cover: Service and Repair

Engine Front Cover

Special Tool(s):

Material:

Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Remove the engine coolant degas bottle.
4. Remove the supercharger (SC) coolant degas bottle.
5. Remove the 4 nuts and the strut tower cross brace.





6. Remove the RH and LH valve covers.
7. Loosen the 4 coolant pump pulley bolts.





8. Remove the accessory drive belt, the 2 accessory drive belt idler pulleys and the accessory drive belt tensioner.
9. Remove the 4 bolts and the coolant pump pulley.
10. Remove the SC drive belt, SC drive belt tensioner and the 3 SC drive belt idler pulleys.
11. Remove the thermostat housing.
12. Remove the crankshaft front seal.
13. Disconnect the 2 coolant vent hoses from the intake manifold.
14. Disconnect the 2 upper radiator hoses from the intake manifold.
15. Disconnect the coolant hoses from the charge air cooler (CAC).
16. Disconnect the lower radiator hose assembly from the coolant pump, radiator, oil filter adapter and the coolant tube assembly (located above the generator).
- Remove the lower radiator hose assembly from the vehicle.
17. Disconnect the A/C pressure transducer electrical connector.
18. Remove the power steering tube bracket nut from the generator stud bolt.
19. Remove the power steering tube bracket bolt from the engine front cover.
20. Remove the 2 bolts from the power steering reservoir bracket.
21. Remove the 3 bolts and position the power steering pump and reservoir assembly aside.
22. Disconnect the crankshaft position (CKP) sensor electrical connector.
23. Install the special tool.





24. Install the special tool.





25. NOTE: The heavy duty 3-bar support (303-F070) must be used with the draw screws from the light duty 3-bar support (303-F072). This will provide enough clearance between the supercharger (SC) and the 3-bar support, and enough clearance between the draw screw and the vehicle hood.

Install the special tools.
1. Remove the LH and RH engine support insulator nuts.
2. Using the special tools, raise the engine.





26. Remove the nut and disconnect the B+ wire terminal from the generator.
27. Disconnect the generator electrical connector.
28. Detach the wiring harness retainer from the oil pan stud bolt.
29. Remove the nut and the wire harness retainer bracket from the oil pan stud bolt.
30. Detach the 2 wiring harness pin-type retainers from the generator.
31. Remove the stud bolt, 2 bolts and the generator.
32. Disconnect the coolant hose from the oil filter adapter.

33. CAUTION: If metal or aluminum foreign material is present in the oil cooler, mechanical concerns exist. To diagnose mechanical concerns, refer to Engine.

Remove the 6 bolts and the oil cooler.
- Discard the gaskets.
- Inspect the oil cooler.
34. Drain the engine oil.
- Tighten the drain plug to 26 Nm (19 ft. lbs.).
35. Remove and discard the engine oil filter.
36. Remove the 3 coolant tube assembly bolts.
37. Disconnect the engine oil pressure (EOP) sensor electrical connector and the 2 wiring harness pin-type retainers.
38. Remove the 8 bolts and the oil filter adapter.
- Discard the gasket.
39. Remove the 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts.
40. Remove the 4 bolts and the coolant pump.
- Discard the gasket.
41. Remove the 16 bolts and the engine front cover.
- Remove and discard the engine front cover gaskets.

- CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Inspect the mating surfaces.





Installation

1. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or 4 minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.

Apply silicone gasket and sealant in the locations shown.





2. Using new gaskets, install the engine front cover and the 16 bolts. Tighten the bolts in the sequence shown:
- Bolts 1 through 14 to 25 Nm (18 ft. lbs.).
- Bolts 15 and 16 to 50 Nm (37 ft. lbs.).





3. Install the 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts.
- Tighten to 25 Nm (18 ft. lbs.).
4. Using a new gasket, install the coolant pump and the 4 bolts.
- Tighten to 25 Nm (18 ft. lbs.).

5. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Using a new gasket, install the oil filter adapter and the 8 bolts.
- Tighten in the sequence shown:
^ Bolts 1 through 6 to 25 Nm (18 ft. lbs.).
^ Bolts 7 and 8 to 50 Nm (37 ft. lbs.).





6. Connect the EOP sensor electrical connector and the 2 wiring harness pin-type retainers.
7. Install the 3 coolant tube assembly bolts.
- Tighten to 10 Nm (89 inch lbs.).
8. Install a new engine oil filter.
1. Lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact.
2. Using an oil filter strap wrench, tighten the filter an additional 270 degrees.

9. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

Using new gaskets, install the oil cooler and the 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 inch lbs.).





10. Connect the coolant hose to the oil filter adapter.
11. Install the generator, 2 bolts and the stud bolt.
- Tighten to 50 Nm (37 ft. lbs.).
12. Attach the 2 wiring harness pin-type retainers to the generator.
13. Install the wire harness retainer bracket on the oil pan stud bolt and install the nut.
- Tighten to 10 Nm (89 inch lbs.).
14. Attach the wiring harness retainer to the oil pan stud bolt.
15. Connect the generator electrical connector.
16. Connect the B+ wire terminal to the generator and install the nut.
- Tighten to 8 Nm (71 inch lbs.).
17. Using the special tools, lower the engine onto the engine support insulators.





18. Install the LH and RH engine support insulator nuts.
- Tighten to 63 Nm (46 inch lbs.).
19. Connect the CKP sensor electrical connector.
20. Install the power steering pump and reservoir assembly and the 3 bolts.
- Tighten to 25 Nm (18 ft. lbs.).
21. Install the 2 power steering reservoir bracket bolts.
- Tighten to 25 Nm (18 ft. lbs.).
22. Install the power steering tube bracket bolt.
- Tighten to 10 Nm (89 inch lbs.).
23. Install the power steering tube bracket nut to the generator stud bolt.
- Tighten to 10 Nm (89 inch lbs.).
24. Connect the A/C pressure transducer electrical connector.
25. Install the lower radiator hose assembly to the coolant pump, radiator, oil filter adapter and the coolant tube assembly (located above the generator).
26. Connect the coolant hoses from the CAC.
27. Connect the 2 upper radiator hoses to the intake manifold.
28. Connect the 2 coolant vent hoses to the intake manifold.
29. Install the crankshaft front seal.
30. Install the thermostat housing.
31. Install the 3 supercharger (SC) drive belt idler pulleys, SC drive belt and the SC drive belt tensioner.
32. Install the coolant pump pulley and the 4 bolts.
33. Install the 2 accessory drive belt idler pulleys, the accessory drive belt tensioner and the accessory drive belt.
34. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 ft. lbs.).
35. Install the RH and LH valve covers.
36. Install the SC coolant degas bottle.
37. Install the engine coolant degas bottle.
38. Install the strut tower cross brace and the 4 nuts.
- Tighten to 35 Nm (26 ft. lbs.).





39. Fill and bleed the SC cooling system.
40. Fill and bleed the engine cooling system.