VIN G00442->G45703

Engine Front Cover - VIN Range: G00442->G45703 (12.65.01)





Removal

All vehicles
1. Remove the cooling fan motor and shroud. Refer to Cooling System.
2. Remove the left-hand valve cover.
3. Remove the right-hand valve cover.

Vehicles without supercharger
4. Remove the oil cooler.

Vehicles with supercharger
5. Remove the supercharger drive belt. Refer to Drive Belts, Mounts, Brackets and Accessories.

All vehicles
6. Remove power steering pump.
7. Remove the air conditioning compressor. Refer to Heating and Air Conditioning.
8. Remove the water pump pulley.





9. Remove the accessory drive belt idler pulley.





Vehicles with supercharger
10. Remove supercharger drive belt tensioner. Refer to Drive Belts, Mounts, Brackets and Accessories.

All vehicles
11. Remove the power steering pump mounting bracket.





12. Detach the engine harness.





13. CAUTION: Under no circumstances should the crankshaft setting peg 303-645 be used in the following operations to lock the crankshaft.

Using special tools, retain the crankshaft pulley.

^ Remove and discard the crankshaft pulley bolt.





14. Remove the special tools.
15. Using special tools, remove the crankshaft pulley. Collect the locking ring.
^ Remove and discard the O-ring seal.





16. Remove the special tools.
17. Remove the engine front cover.
^ Remove and discard all the seals.





Installation

All vehicles
1. Install new seals to the timing cover.
1) Install the new seal to the inner groove on the face of the timing cover.
2) Install the new seal to the outer groove on the face of the timing cover.





2. Apply sealant to the eight joints on the engine face.
^ Sealant beads to be 3 mm diameter and 12 mm long. Cut the nozzle of the sealant tube to produce a 3 mm (0.12 in) bead. (Install and tighten the securing bolts within twenty minutes of sealant application).





3. Install the timing cover.
^ Tighten in the sequence shown.
^ Tighten to 13 Nm.





4. NOTE: Check crankshaft pulley and locking ring for damage.

Clean all crankshaft pulley mating faces.





5. CAUTION: The screw thread in the crankshaft must be cleaned out before a new crankshaft pulley bolt is installed.

CAUTION: A new crankshaft pulley bolt must be used.

Install, but do not tighten, a new crankshaft pulley retaining bolt.

^ Install the crankshaft pulley and locking ring to the crankshaft.





6. CAUTION: Under no circumstances should the crankshaft setting peg 303-645 be used in the following operations to lock the crankshaft.

Using special tools, retain the crankshaft pulley.

^ Tighten the crankshaft pulley retaining bolt to 375 Nm.





7. Remove the special tools.
8. Attach the engine harness.





9. Install the power steering pump mounting bracket.
^ Tighten to 25 Nm





10. Install the accessory drive belt idler pulley.
^ Tighten to 25 Nm.





Vehicles with supercharger
11. Install the supercharger drive belt tensioner. Refer to Drive Belts, Mounts, Brackets and Accessories.

All vehicles
12. Install the water pump pulley.
^ Tighten to 10 Nm + 45°.





13. Install the air conditioning compressor. Refer to Heating and Air Conditioning.
14. Install power steering pump.

Vehicles with supercharger
15. Install the supercharger drive belt. Refer to Drive Belts, Mounts, Brackets and Accessories.

Vehicles without supercharger
16. Install the oil cooler.

All vehicles
17. Install the left-hand valve cover.
18. Install the right-hand valve cover.
19. Install the cooling fan motor and shroud. Refer to Cooling System.