Timing Cover: Service and Repair

Engine Front Cover









Engine Front Cover (View 1 of 4)










Engine Front Cover (View 2 of 4)










Engine Front Cover (View 3 of 4)










Engine Front Cover (View 4 of 4)









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 RH and LH valve covers. For additional information, refer to Valve Cover- RH Valve Cover - RH and Valve Cover- LH Valve Cover - LH.

6. Loosen the 4 coolant pump pulley bolts.





7. Remove the accessory drive belt, the 2 accessory drive belt idler pulleys and the accessory drive belt tensioner.

8. Remove the 4 bolts and the coolant pump pulley.

9. Remove the SC (Supercharger) drive belt, SC (Supercharger) drive belt tensioner and the 3 SC (Supercharger) drive belt idler pulleys.

10. Remove the thermostat housing.

11. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal Crankshaft Front Seal.

12. Disconnect the 2 coolant vent hoses from the intake manifold.

13. Disconnect the 2 upper radiator hoses from the intake manifold.

14. Disconnect the coolant hoses from the Charge Air Cooler (CAC).

15. 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.


16. Disconnect the A/C pressure transducer electrical connector.

17. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

18. Install the Engine Lifting Bracket.





19. Install the Engine Lifting Bracket.





20. NOTE: The heavy duty Engine Support Bar (303-F070) must be used with the draw screws from the light duty Engine Support Bar (303-F072). This will provide enough clearance between the SC (Supercharger) and the Engine Support Bar, and enough clearance between the draw screw and the vehicle hood.
Install the Engine Support Bars.

- Remove the LH and RH engine support insulator nuts.

- Using the Engine Support Bars, raise the engine.






21. Remove the 3 bolts and lower the underbody shield.





22. Remove the nut and disconnect the B+ wire terminal from the generator.

23. Disconnect the generator electrical connector.

24. Detach the wiring harness retainer from the oil pan stud bolt.

25. Remove the nut and the wire harness retainer bracket from the oil pan stud bolt.

26. Remove the 3 bolts and the generator.

27. Disconnect the coolant hose from the oil filter adapter.

28. NOTICE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. To diagnose mechanical concerns, refer to Engine.

Remove the 6 bolts and the oil cooler.
- Discard the gaskets.

- Inspect the oil cooler.


29. Drain the engine oil.
- Tighten the drain plug to 26 Nm (19 lb-ft).


30. Remove and discard the engine oil filter.

31. Remove the 3 coolant tube assembly bolts.

32. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness pin-type retainers.

33. Remove the 8 bolts and the oil filter adapter.
- Discard the gasket.


34. Remove the oil pan-to-engine front cover bolt and the 3 oil pan-to-engine front cover stud bolts.

35. Remove the 4 bolts and the coolant pump.
- Discard the gasket.


36. Remove the 16 bolts and the engine front cover.
- Remove and discard the engine front cover gaskets.

- NOTICE: 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: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone sealer to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.






2. NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.
Using new gaskets, position the engine front cover onto the dowels and install the 16 bolts. Tighten the bolts in the sequence shown:
Bolts 1 through 14 to 25 Nm (18 lb-ft).
Bolts 15 and 16 to 50 Nm (37 lb-ft).









3. Install the oil pan-to-engine front cover bolt and the 3 oil pan-to-engine front cover stud bolts.
- Tighten to 25 Nm (18 lb-ft).


4. Using a new gasket, install the coolant pump and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).


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 lb-ft).

- Bolts 7 and 8 to 50 Nm (37 lb-ft).






6. Connect the EOP (Engine Oil Pressure) switch electrical connector and the 2 wiring harness pin-type retainers.

7. Install the 3 coolant tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).


8. Install a new engine oil filter in the following sequence.
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 lb-in).






10. Connect the coolant hose to the oil filter adapter.

11. Install the generator and the 3 bolts.
- Tighten to 50 Nm (37 lb-ft).


12. Install the 2 wire harness retainer brackets on the 2 oil pan stud bolts and install the 2 nuts.
- Tighten to 10 Nm (89 lb-in).


13. Attach the wiring harness retainer to the oil pan stud bolt.

14. Connect the generator electrical connector.

15. Connect the B+ wire terminal to the generator and install the nut.
- Tighten to 8 Nm (71 lb-in).


16. Position the underbody shield and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).






17. Using the Engine Support Bars, lower the engine onto the engine support insulators.





18. Install the LH and RH engine support insulator nuts.
- Tighten to 63 Nm (46 lb-ft).


19. Connect the CKP (Crankshaft Position) sensor electrical connector.

20. Connect the A/C pressure transducer electrical connector.

21. Install the lower radiator hose assembly to the coolant pump, radiator, oil filter adapter and the coolant tube assembly (located above the generator).

22. Connect the coolant hoses from the CAC (Charge Air Cooler).

23. Connect the 2 upper radiator hoses to the intake manifold.

24. Connect the 2 coolant vent hoses to the intake manifold.

25. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal Crankshaft Front Seal.

26. Install the thermostat housing.

27. Install the 3 SC (Supercharger) drive belt idler pulleys, SC (Supercharger) drive belt and the SC (Supercharger) drive belt tensioner.

28. Install the coolant pump pulley and the 4 bolts.

29. Install the 2 accessory drive belt idler pulleys, the accessory drive belt tensioner and the accessory drive belt.

30. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).

31. Install the RH and LH valve covers. For additional information, refer to Valve Cover- RH Valve Cover - RH and Valve Cover- LH Valve Cover - LH.

32. Install the SC (Supercharger) coolant degas bottle.

33. Install the engine coolant degas bottle.

34. Fill the engine with clean engine oil.

35. Fill and bleed the SC (Supercharger) cooling system. For additional information, refer to Cooling System.

36. Fill and bleed the engine cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.

37. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.