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Engine Front Cover Replacement

Special Tools

EN-50435 Guide Pin

For equivalent regional tools, refer to Special Tools .

Removal Procedure

  1. Remove camshaft cover. Refer to Camshaft Cover Replacement .
  2. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  3. Remove the crankshaft pulley. Refer to Crankshaft Pulley Replacement .
  4. Remove the oil filter adapter. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement .
  5. Remove the upper oil pan. Refer to Upper Sump Replacement .
  6. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement .
  7. Remove the charge air control vacuum hose

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  9. Remove 16 engine front cover retaining bolts (2, 3).
  10. Note: Detach carefully from engine block using suitable tool. Do not damage sealing surfaces.

  11. Remove the engine front cover (1).

Installation Procedure

  1. Remove any old sealant and gasket material with a suitable tool.
  2. Clean the front cover and front cover components with solvent.
  3. Note: Ensure that the sealing surface is clear of oil, grease and old sealing material.

  4. Clean out debris from the bolt holes.
  5. Warning: Refer to Safety Glasses and Compressed Air Warning in the Preface section.

  6. Dry the front cover and front cover components with compressed air.
  7. Note: The complete installation procedure of the engine front cover should be done in 10 minutes.

    Note: Do not coat sealing compound on the engine front cover bolt holes and bolt threads.


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  8. Apply sealing compound on sealant line (1), 2 hole faces (2) and 2 areas (3).
  9. Apply sealing compound to the edge of chamfer (4).

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    Note: The alignment pins will help maintaining position while installing the bolts.

  11. To aid in cover alignment, install 2 EN-50435 guide pins on the engine block.
  12. Install the engine front cover (1).
  13. Caution: Refer to Fastener Caution in the Preface section.

  14. Install the engine front cover bolts and remove the EN-50435 guide pins .
  15. Install 13 engine front cover retaining bolts (M8) (3). Tighten the bolts evenly to 22 N·m (16 lb ft).
  16. Install 3 engine cover retaining bolts (M6) (2). Tighten the bolts to 9 N·m (80 lb in).
  17. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .
  18. Install camshaft cover. Refer to Engine Front Cover Removal .
  19. Install the oil filter adapter. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement .
  20. Install the crankshaft pulley. Refer to Crankshaft Pulley Replacement .
  21. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  22. Install the upper oil sump . Refer to Upper Sump Replacement .
   


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