Engine Front Cover

Special Tool(s)

	3 Jaw Puller 303-D121
	Alignment Pins 307-399
	Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
	Installer, Front Crankshaft Seal 303-1251
	Remover, Oil Seal 303-409 (T92C-6700CH)
	Replacer, Crankshaft Vibration Damper 303-102 (T74P-6312-B)
	Strap Wrench 303-D055 (D85L-6000-A)
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.
   • Detach the HO2S connector retainer from the bracket.

3. Remove the LH and RH valve cover. For additional information, refer to Valve Cover — LH and Valve Cover — RH in this section.

4. Remove the 4 retainers and the underbody shield.

5. Remove the RH inner fender splash shield. For additional information, refer to Section 501-02 .

6. Remove the accessory drive belt and tensioner. For additional information, refer to Section 303-05 .

7. Loosen the rear roll restrictor bolt.

8. Remove the 2 bolts and the rear roll restrictor bracket.

9. Remove the front roll restrictor bolt.

10. Remove the oil pan drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).

11. Using the Strap Wrench, remove the crankshaft bolt and washer.
    • Discard the bolt.

12. Using the 3 Jaw Puller, remove the crankshaft pulley.

13. Using the Oil Seal Remover, remove and discard the crankshaft front seal.

14. Remove the engine mount. For additional information, refer to Engine Mount in this section.

15. Detach the RH Heated Oxygen Sensor (HO2S) electrical connector from the bracket.
    • Remove the stud bolt and the bracket.

16. Using the floor jack, raise the engine slightly.

17. Remove the 2 upper engine mount bracket bolts.

18. Using the floor jack, lower the engine slightly.

19. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.

20. Remove the 22 engine front cover bolts.

21. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover.
    1. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
    2. Remove the engine front cover.

Installation

1. NOTICE: Only use a 3M™ Roloc® Bristle Disk (2 in white, part number 07528), to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover.

   Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2 in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
   • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

2. NOTICE: Place clean, lint free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

   NOTICE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces of the engine block, cylinder heads, and oil pan. These tools cause contamination that can cause premature engine failure. Remove all traces of sealant, including any sealant from the inner surface of the cylinder block and cylinder head.

   NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

   
   Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
   1. Remove any large deposits of silicone or gasket material with a plastic scraper.
   2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
   3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
   4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
   5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

3. Install the Alignment Pins.

4. NOTICE: Failure to use the correct RTV Silicone Sealant (TA-357) may cause the engine oil to foam excessively and result in serious engine damage.

   NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. 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 3.0 mm (0.11 in) bead of RTV Silicone Sealant (TA-357) to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
   • Apply a 5.5 mm (0.21 in) bead of RTV Silicone Sealant (TA-357) to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.

5. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

   Install the engine front cover and bolts 17, 18, 19 and 20.
   • Tighten in sequence to 3 Nm (27 lb-in).

6. Remove the Alignment Pins.

7. Install the engine mount bracket and lower bolt.
   • Do not tighten at this time.

8. Using the floor jack, raise the engine slightly.

9. Install the 2 upper engine mount bracket bolts.
   • Do not tighten at this time.

10. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).

11. Install the HO2S connector bracket and stud bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Attach the HO2S electrical connector.

12. Install the engine mount. For additional information, refer to Engine Mount in this section.

13. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

    Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.

14. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

    Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.

15. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.

16. NOTE: The bracket has keyed tabs to orient the roll restrictor.

    Position the rear roll restrictor bracket with the keyed tabs aligned to the rear roll restrictor and install the bolts.
    • Tighten to 103 Nm (76 lb-ft).

17. Tighten the rear roll restrictor bolt to 103 Nm (76 lb-ft).

18. Install the front roll restrictor bolt.
    • Tighten to 103 Nm (76 lb-ft).

19. Install the accessory drive belt tensioner and belt. For additional information, refer to Section 303-05 .

20. Install the RH inner fender splash shield. For additional information, refer to Section 501-02 .

21. Install the underbody shield and the 4 retainers.

22. Install the RH and LH valve covers. For additional information, refer to Valve Cover — RH and Valve Cover — LH in this section.

23. Connect the LH HO2S electrical connector.
    • Attach the HO2S connector retainer to the bracket.

24. NOTICE: Do not expose the RTV Silicone Sealant to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

    Fill the engine with clean engine oil.

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