REMOVAL & INSTALLATION
Inline 6-Cylinder Engines
See Figures 1 and 2
- Drain the engine coolant, remove the radiator hoses, and remove the radiator.
- Remove the fan belt and any accessory belts. Remove the fan pulley.
- A harmonic balancer/torsional damper puller is necessary to pull the balancer. Install the puller and remove the balancer/damper.
- Remove the two screws which attach the oil pan to the front cover. Remove the screws which attach the front cover to the block. Do not remove the cover yet.
- Before the front cover is removed, it is necessary to cut the oil pan front seal. Pull the cover forward slightly.
- Using a sharp knife or razor knife, cut the oil pan front seal flush with the cylinder block on both sides of the cover.
- Remove the front cover and the attached portion of oil pan front seal. Remove the front cover gasket from the block.
- To install the front cover, first obtain an oil pan front seal. Cut the tabs from the new seal.
- Install the seal in the front cover, pressing the tips into the holes provided in the cover. Coat the mating area of the front cover with a room temperature vulcanizing (RTV) sealer first.
- Coat the new front cover gasket with sealer and install it on the cover.
- Apply a 1 / 8 in. bead of RTV sealer to the joint formed at the oil pan and cylinder block.
- Install the front cover.
- Install the harmonic balancer. Make sure the front cover seal is positioned evenly around the balancer. If you do not have access to a balancer installation tool (and you probably don't) you can either fabricate one using the illustration as a guide, or you can tap the balancer on using a brass or plastic mallet. If you use the last method, make sure the balancer goes on evenly.
- The rest of the installation is in the reverse order of removal.
EXCEPT DIESEL ENGINES
See Figures 3 through 13
- Drain the cooling system.
- Remove the crankshaft pulley and damper, using Tool J-23523 Damper Pulley remover and installer.
- Remove the water pump.
- Unfasten the screws holding the timing case cover to the block, then remove the cover and gaskets.
- Thoroughly clean the gasket mating surfaces.
- Use a suitable tool to pry the old seal out of the front face of the cover.
- Install the new seal so that the open end is toward the inside of the cover, using Tool J-35468 Seal installer.
Coat the lip of the new seal with oil prior to installation.
- Check that the timing chain oil slinger is in place against the crankshaft sprocket.
- Apply sealer to the front cover as shown in the accompanying illustration. Install the cover carefully onto the locating dowels.
- Tighten the attaching screws to 6-8 ft. lbs. (8-11 Nm).
- Install the damper pulley using Tool J-23523 Damper Pulley installer and tighten the retaining bolt to specifications. (See the Torque Specifications Chart).
See Figures 14 and 15
- Drain the cooling system and disconnect the radiator hoses.
- Remove all belts, fan and pulley, crankshaft pulley and balancer, using a balancer puller.
- Unbolt and remove the cover, timing indicator and water pump.
- It may be necessary to grind a flat on the cover for gripping purposes.
- Grind a chamfer on one end of each dowel pin.
- Cut the excess material from the front end of the oil pan gasket on each side of the block.
- Clean the block, oil pan and front cover mating surfaces with solvent.
- Trim about 1 / 8 in. off each end of a new front pan seal.
- Install a new front cover gasket on the block and a new seal in the front cover.
- Apply sealer to the gasket around the coolant holes.
- Apply sealer to the block at the junction of the pan and front cover.
- Place the cover on the block and press down to compress the seal. Rotate the cover left and right and guide the pan seal into the cavity using a small screwdriver. Oil the bolt threads and install two bolts to hold the cover in place. Install both dowel pins (chamfered end first), then install the remaining front cover bolts.
- Apply a lubricant, compatible with rubber, on the balancer seal surface.
- Install the balancer and bolt. Tighten the bolt to 200-300 ft. lbs. (271-406 Nm).
- Install the other parts in the reverse order of removal.