Special Tools

J 37228 Seal Cutter

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the water pump. Refer to Water Pump Replacement.
3. Remove the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement.
4. Disconnect the crankshaft position (CKP) sensor electrical connector.




Note: The CKP sensor spacers are machined with different timing positions. If the spacer requires replacement, replace it with the same part number spacer. For LLY engines, use C grade spacer when replacing a spacer.

5. Remove the CKP sensor bolt and sensor.
6. Remove the CKP sensor spacer bolts and spacer.
7. Remove and discard the O-rings from the sensor and the spacer.



8. Remove the upper oil pan to engine front cover bolts.



9. Remove the engine front cover bolts.
10. Separate the engine front cover from the cylinder block and upper oil pan using J 37228 .

Note: Do not bend the turbocharger coolant pipe.

11. Remove the engine front cover.



12. If necessary, remove the pressure relief valve O-ring.
13. Clean and inspect the front cover. Refer to Engine Front Cover Cleaning and Inspection.

Caution: Refer to Fastener Caution in the Preface section.




1. If necessary, install a NEW pressure relief valve O-ring.
2. Lubricate the O-ring with engine oil.

Tighten
Tighten the valve to 39 N·m (29 lb ft).




3. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high, bead of sealant to the engine front cover sealing surface to the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
4. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high, bead of sealant to the engine front cover sealing surface to the upper oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.



5. Install the engine front cover.
6. Install the engine front cover bolts.

Tighten
Tighten the bolts to 2 N·m (15 lb ft).




7. Install the upper oil pan to engine front cover bolts.

Tighten
Tighten the bolts to 21 N·m (15 lb ft).




8. Install a NEW O-ring to the CKP sensor spacer.
9. Lubricate the O-ring with clean engine oil.

Note: The CKP sensor spacers are machined with different timing positions. If the spacer requires replacement, replace it with the same part number spacer. For LLY engines, use C grade spacer when replacing a spacer.

10. Install the CKP sensor spacer and bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

11. Install a NEW O-ring to the CKP sensor.
12. Lubricate the O-ring with clean engine oil.
13. Install the CKP sensor and bolt.

Tighten
Tighten the bolt to 10 N·m (89 lb in).




14. Connect the CKP sensor electrical connector.
15. Install the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement.
16. Install the water pump. Refer to Water Pump Replacement.
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.