Engine Front Cover Replacement First Design

Tools Required

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

1. Remove the generator. Refer to Generator Replacement .
2. Remove the power steering pump. Refer to Power Steering Pump Replacement .
3. Remove the coolant pump manifold. Refer to Coolant Pump Manifold Replacement .
4. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
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 (501).
8. Remove the front cover (502) and gasket (503).
9. Discard the front cover gasket.



10. Remove the oil seal (140), if necessary.
11. Remove the camshaft position (CMP) sensor bolt (705) and sensor (703), if necessary.
12. Remove the O-ring seal (704) from the sensor, if necessary.
13. Clean and inspect the engine front cover. Refer to Engine Front Cover Cleaning and Inspection .

Important: 

1. Apply a 5 mm (0.20 in) bead of sealant or equivalent 20 mm (0.80 in) long to the oil pan to engine block junction. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
2. Install the front cover gasket (503) and cover (502).
3. Install the front cover bolts until snug (502). Do not overtighten.
4. Install the oil pan-to-front cover bolts until snug. Do not over tighten.



5. Install the J 41476 to the front cover.
6. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the crankshaft balancer bolt until snug. Do not overtighten.

Tighten

•	Tighten the oil pan to front cover bolts to 25 N·m (18 lb ft).

•	Tighten the engine front cover bolts to 25 N·m (18 lb ft).

8. Remove the J 41476 .



9. Install a NEW crankshaft front oil seal (140). Refer to Crankshaft Front Oil Seal Replacement .
10. Install the coolant pump manifold. Refer to Coolant Pump Manifold Replacement .
11. Inspect the CMP sensor O-ring seal (704) for cuts or damage. If the seal is not cut or damaged, it may be reused.
12. Lubricate the O-ring seal with clean engine oil.
13. Install the O-ring seal (704) onto the CMP sensor.
14. Install the CMP sensor (703) and bolt (705) from the front cover.

Tighten
Tighten the bolt to 12 N·m (106 lb in).

15. Position the belt tensioner and install the bolt.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).

16. Install the power steering pump. Refer to Power Steering Pump Replacement .
17. Install the generator. Refer to Generator Replacement .

Engine Front Cover Replacement Second Design

Tools Required

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

1. Remove the generator. Refer to Generator Replacement .
2. Remove the power steering pump. Refer to Power Steering Pump Replacement .
3. Remove the coolant pump manifold. Refer to Coolant Pump Manifold Replacement .
4. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
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.

Important: 

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

Notice: Refer to Fastener Notice in the Preface section.





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

3. Install the J 41480 .

Tighten
Tighten the tool-to-engine block bolts to 25 N·m (18 lb ft).





Important: 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.

Tighten

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 N·m (18 lb ft).
6. Remove the tools.



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

7.1.	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.

7.2.	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
Tighten the bolt to 12 N·m (106 lb in).

15. Install the coolant pump manifold. Refer to Coolant Pump Manifold Replacement .
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
Tighten the bolt to 12 N·m (106 lb in).

20. Position the belt tensioner and install the bolt.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).

21. Install the power steering pump. Refer to Power Steering Pump Replacement .
22. Install the generator. Refer to Generator Replacement .