Engine Front Cover Replacement (L84 with WTX)

Single Use Fasteners and Components Accessory Drive Auxiliary Belt Accessory Drive Primary Belt Camshaft Position Actuator Magnet Gasket Camshaft Position Sensor Seal Crankshaft Balancer Bolt Crankshaft Front Oil Seal Engine Oil Cooler Retainer [2x] Oil Filter Water Pump Gasket [2x] Special Tools EN-956-1 Extension Bar EN-28410 Remover EN-41478-A Crankshaft Front Oil Seal Installer EN-41665-A Crankshaft Balancer and Sprocket Installer EN-41816-A Crankshaft Balancer Remover EN-44226-5 Crankshaft Protector EN-51091 Crankshaft Front Oil Seal Installer EN-51096 Seal Remover EN-51767-2 Stretchy Belt Installer EN-52287 Balancer Holding Kit GE-23907-1 Slide Hammer with Shaft Equivalent regional tools: Special Tools Removal Procedure

1. Remove the negative battery cable from the battery. Battery Negative Cable Disconnection and Connection

Engine Front Cover Replacement (L84 with WTX) — figure 1

2. Air Cleaner Outlet Duct Bracket Bolt (1) » Remove
3. Remove engine wiring harness from air cleaner outlet duct bracket.

Engine Front Cover Replacement (L84 with WTX) — figure 2

4. Positive Crankcase Ventilation Fresh Air Tube (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
5. Air Cleaner Outlet Duct Clamp (2) » Loosen [2x]
6. Air Cleaner Outlet Duct (3) » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 3

Note

The accessory drive primary belt is not reusable.

7. Using a suitable tool, cut the accessory drive primary belt (1).
8. Accessory Drive Primary Belt (1) » Remove and DISCARD

Engine Front Cover Replacement (L84 with WTX) — figure 4

Note

The accessory drive auxiliary belt is not reusable.

9. Using a suitable tool, cut the accessory drive auxiliary belt (1).
10. Accessory Drive Auxiliary Belt (1) » Remove and DISCARD

Engine Front Cover Replacement (L84 with WTX) — figure 5

11. Battery Positive Cable Nut (1) » Remove
12. Starter Solenoid Cable (2) » Remove
13. Electrical Connector (3) » Disconnect
14. Raise and support the vehicle. Lifting and Jacking the Vehicle
15. Drain the cooling system. Cooling System Draining and Filling
16. Engine Oil and Oil Filter » Remove and DISCARD — Engine Oil and Oil Filter Replacement

Engine Front Cover Replacement (L84 with WTX) — figure 6

17. Front Bumper Fascia Air Deflector Bolt (1) » Remove [10x]
18. Front Bumper Fascia Extension Bolt (2) » Remove [8x]

Engine Front Cover Replacement (L84 with WTX) — figure 7

19. Pull the front bumper fascia extension (1) rearward and down from the front bumper fascia.

Engine Front Cover Replacement (L84 with WTX) — figure 8

20. Front Bumper Fascia Extension Bracket (2) » Remove [4x]
21. Front Bumper Fascia Extension Bolt (3) @ Underbody Skid Shield » Remove [2x]
22. Front Bumper Fascia Extension (4) » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 9

23. Underbody Skid Shield Bolt (1) » Remove [2x]
24. Underbody Skid Shield (2) » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 10

25. Engine Oil Cooler Hose Clip (1) » Release

Engine Front Cover Replacement (L84 with WTX) — figure 11

Note

It is not necessary to recover and recharge the refrigerant to perform this repair.

26. Air Conditioning Compressor Bolt (1) » Remove
27. Air Conditioning Compressor Nut (2) » Remove
28. Air Conditioning Compressor Stud (3) » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 12

29. Air Conditioning Compressor Assembly (1) » Position aside

Engine Front Cover Replacement (L84 with WTX) — figure 13

Note

The balancer holding kit (4) should be assembled as it is installed on the crankshaft balancer (2). Some components not shown for graphic clarity.

30. Install the EN-52287 Balancer Holding Kit (4) and the EN-956-1 Extension Bar (3) to the crankshaft balancer (2).
31. Hold the EN-52287 Balancer Holding Kit (4) with the EN-956-1 Extension Bar (3) and remove and DISCARD the crankshaft balancer bolt (1).
32. Remove the EN-52287 Balancer Holding Kit (4) and the EN-956-1 Extension Bar (3) from the crankshaft balancer (2).

Engine Front Cover Replacement (L84 with WTX) — figure 14

33. Install the EN-41816-A Crankshaft Balancer Remover (1) and the EN-44226-5 Crankshaft Protector (3) to the crankshaft balancer (2).

Engine Front Cover Replacement (L84 with WTX) — figure 15

34. Using the EN-41816-A Crankshaft Balancer Remover (1) with the EN-44226-5 Crankshaft Protector (2) remove crankshaft balancer (3) from the crankshaft.
35. Remove the EN-41816-A Crankshaft Balancer Remover (1) and the EN-44226-5 Crankshaft Protector (2) from the crankshaft balancer (3).
36. Remove the support and lower the vehicle.

Engine Front Cover Replacement (L84 with WTX) — figure 16

37. Radiator Surge Tank Outlet Hose Clip (2) » Remove [2x]
38. Radiator Surge Tank Outlet Hose (3) » Position aside

Engine Front Cover Replacement (L84 with WTX) — figure 17

39. Radiator Inlet Hose Clip (2) » Remove
40. Radiator Inlet Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
41. Radiator Inlet Hose (3) @ Engine Radiator » Remove and position aside

Engine Front Cover Replacement (L84 with WTX) — figure 18

42. Wiring Harness Retainer (1) » Remove [2x]
43. Electrical Connector (3) » Disconnect
44. Wiring Harness (2) » Position aside

Engine Front Cover Replacement (L84 with WTX) — figure 19

45. Wiring Harness Retainer (2) » Remove [2x]
46. Electrical Connector (1) » Disconnect
47. Wiring Harness (3) » Position aside

Engine Front Cover Replacement (L84 with WTX) — figure 20

48. Engine Oil Cooler Retainer (2) » Remove and DISCARD [2x]
49. Engine Oil Cooler Pipe Bracket Bolt (3) » Remove
50. Engine Oil Cooler Hose (1) @ Engine Radiator » Remove [2x]

Engine Front Cover Replacement (L84 with WTX) — figure 21

51. Transmission Fluid Cooler Pipe Bolt (1) » Remove
52. Transmission Fluid Cooler Pipe Clip (2) » Remove [2x]

Engine Front Cover Replacement (L84 with WTX) — figure 22

53. Transmission Fluid Cooler Pipe Clip (1) » Release

Engine Front Cover Replacement (L84 with WTX) — figure 23

54. Engine Coolant Fan Bracket Bolt (1) » Remove [2x]

Engine Front Cover Replacement (L84 with WTX) — figure 24

55. Engine Cooler Fan (1) @ Engine Radiator » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 25

56. Generator Bolt (1) » Remove
57. Generator Bolt (2) » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 26

58. Generator (1) » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 27

59. Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines - Spring Type
60. Heater Inlet Hose (2) @ Water Pump » Remove
61. Heater Water Auxiliary Pump Hose (3) @ Water Pump » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 28

62. Radiator Outlet Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
63. Radiator Outlet Hose (2) @ Water Pump » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 29

64. Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines - Spring Type
65. Engine Coolant Air Bleed Hose (2) @ Water Pump » Remove
66. Radiator Inlet Hose (3) @ Water Pump » Remove

Engine Front Cover Replacement (L84 with WTX) — figure 30

67. Engine Coolant Temperature Sensor Electrical Connector (1) » Disconnect

Engine Front Cover Replacement (L84 with WTX) — figure 31

68. Water Pump Bolt (1) » Remove [6x]

Engine Front Cover Replacement (L84 with WTX) — figure 32

69. Water Pump (1) » Remove
70. Water Pump Gasket (2) » Remove and DISCARD [2x]

Engine Front Cover Replacement (L84 with WTX) — figure 33

Note

If the engine front cover is reused, the crankshaft front oil seal must be replaced.

71. If the engine front cover is reused perform the following steps: 71.1. Install the EN-51096 Seal Remover (2) to the GE-23907-1 Slide Hammer with Shaft (1).

Note

EN-51096 Crankshaft Seal Remover (2) has two ends. The end with the larger bend will be used to remove the crankshaft front oil seal (3). 71.2. Slide the large bend of the EN-51096 Seal Remover (2) between the lip of the crankshaft front oil seal and crankshaft. Ensure that the larger bend of the EN-51096 Crankshaft Seal Remover (2) engages the rear side of the crankshaft front oil seal (3). 71.3. Using the EN-51096 Seal Remover (2) and the GE-23907-1 Slide Hammer with Shaft (1) remove the crankshaft front oil seal (3).

Engine Front Cover Replacement (L84 with WTX) — figure 34

71.4. Crankshaft Front Oil Seal (1) » Remove and DISCARD

Engine Front Cover Replacement (L84 with WTX) — figure 35

72. Electrical Connector (1) » Disconnect
73. Oil Pan Bolt (2) » Remove [2x]

Engine Front Cover Replacement (L84 with WTX) — figure 36

74. Engine Front Cover Bolt (2, 3) » Remove [10x]
75. Engine Front Cover (1) » Remove Cleaning and Inspection Procedure - Required Engine Front Cover

Engine Front Cover Replacement (L84 with WTX) — figure 37

Note

Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

1. Clean the cover in solvent. Remove the sealant from the front cover to the oil pan surface.
2. Dry the cover with compressed air.
3. Inspect the gasket sealing surfaces (1) for excessive scratches or gouging.
4. Inspect the threaded bolt holes (2, 3, 5) for damaged threads or debris.
5. Inspect the camshaft position sensor pass-thru hole and sealing surface (4) for excessive scratches or gouging.
6. Inspect the oil flow control valve connector pass-thru hole and sealing surface (6) for excessive scratches or gouging. Water Pump

Engine Front Cover Replacement (L84 with WTX) — figure 38

1. Clean all excess dirt and debris from the water pump (1).
2. Inspect the water pump (1) for the following conditions: 2.1. Water pump gasket and hose sealing surfaces for excessive scratches or gouging 2.2. Restrictions within the internal coolant passages 2.3. Excessive side-to-side play in the pulley shaft 2.4. Leakage at the water inlet housing or rear cover 2.5. Leakage at the water outlet housing or water pump outlet 2.6. Leakage at the water pump vent hole A stain around the vent hole is acceptable. If leakage or dripping occurs with the engine running and the cooling system pressurized, replace the water pump (1). 2.7. Wear or damage in the belt tracking area of the water pump pulley Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Engine Front Cover Replacement (L84 with WTX) — figure 39

1. Clean the crankshaft balancer (1) in solvent.
2. Clean the belt grooves of all dirt or debris with a wire brush.
3. Dry the crankshaft balancer (1) with compressed air.
4. Inspect the crankshaft balancer (1) for the following conditions: 4.1. Worn, grooved, or damaged hub seal surface 4.2. A crankshaft balancer (1) hub seal surface with excessive scoring, grooves, rust or other damage must be replaced. 4.3. Minor imperfections on the crankshaft balancer (1) hub seal surface may be removed with polishing compound or fine grade emery cloth.

Note

In order for the belt to track properly, the belt grooves should be free of all dirt or debris. 4.4. Dirty or damaged belt grooves: The crankshaft balancer (1) belt grooves should be free of any nicks, gouges, or other damage that may not allow the belt to track properly. 4.5. Minor imperfections may be removed with a fine file. 4.6. Worn, chunking, or deteriorated rubber between the hub and pulley. Installation Procedure

Engine Front Cover Replacement (L84 with WTX) — figure 40

Note

Install and align the front cover within 10 minutes of applying the sealer.

Note

Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant

1. Apply a 3 mm (0.118 in) bead of RTV sealant on the engine front cover as shown (1). Apply a 5 mm (0.197 in) bead of RTV sealant on the engine front cover as shown (2). Adhesives, Fluids, Lubricants, and Sealers

Engine Front Cover Replacement (L84 with WTX) — figure 41

2. Apply a 3 mm (0.118 in) bead of RTV sealant (1) to the engine oil pan (2). Adhesives, Fluids, Lubricants, and Sealers

3. Engine Front Cover (1) » Install

4. Engine Front Cover Bolt (2, 3) » Install and hand tighten [10x]

Caution

Refer to Fastener Caution.

5. Engine Front Cover Bolt (2, 3) » Tighten in sequence [10x] — Fastener Specifications

Engine Front Cover Replacement (L84 with WTX) — figure 42

Note

If the engine front cover is reused, the crankshaft front oil seal must be replaced.

6. If the engine front cover is reused perform the following steps:

Note

For proper orientation, note the installation direction of the crankshaft front oil seal. The crankshaft front oil seal is a reverse-lip design. Install with “THIS SIDE OUT” displayed as shown. Do NOT lubricate the crankshaft front oil seal sealing surface. 6.1. Install the EN-41478-A Crankshaft Front Oil Seal Installer (1) to the EN-51091 Crankshaft Front Oil Seal Installer (2). 6.2. Install the NEW crankshaft front oil seal (3) with “THIS SIDE OUT” facing away from the engine to the EN-51091 Crankshaft Front Oil Seal Installer (2). 6.3. Install the EN-41478-A Crankshaft Front Oil Seal Installer (1) and the EN-51091 Crankshaft Front Oil Seal Installer (2) into the crankshaft. 6.4. Rotate the EN-51091 Crankshaft Front Oil Seal Installer (2) clockwise until the NEW crankshaft front oil seal (3) enters the engine front cover and seats into the bottom of the engine front cover. 6.5. Remove the EN-41478-A Crankshaft Front Oil Seal Installer (1) and the EN-51091 Crankshaft Front Oil Seal Installer (2) from the crankshaft and engine front cover. 6.6. Inspect the crankshaft front oil seal for proper installation. The crankshaft front oil seal should be installed evenly and completely into the engine front cover.

7. Oil Pan Bolt (2) » Install and tighten [2x] — Fastener Specifications
8. Electrical Connector (1) » Connect
9. Raise and support the vehicle.

Engine Front Cover Replacement (L84 with WTX) — figure 43

10. Crankshaft Balancer (1) » Loosely install

Engine Front Cover Replacement (L84 with WTX) — figure 44

11. Install the EN-41478-A Crankshaft Front Oil Seal Installer (3) and the EN-41665-A Crankshaft Balancer and Sprocket Installer (2) to the crankshaft.
12. Using the EN-41665-A Crankshaft Balancer and Sprocket Installer (2), properly seat the crankshaft balancer (1).
13. Remove the EN-41478-A Crankshaft Front Oil Seal Installer (3) and the EN-41665-A Crankshaft Balancer and Sprocket Installer (2).

Engine Front Cover Replacement (L84 with WTX) — figure 45

Note

The balancer holding kit (1) should be assembled as it is installed on the crankshaft balancer (3). Some components not shown for graphic clarity.

14. Install the EN-52287 Balancer Holding Kit (1) and EN-956-1 Extension Bar (2) to the crankshaft balancer (3).

Engine Front Cover Replacement (L84 with WTX) — figure 46

15. Crankshaft Balancer Bolt (1) » Install NEW and tighten — Fastener Specifications

16. Remove the EN-52287 Balancer Holding Kit (3) and the EN-956-1 Extension Bar (4) from the crankshaft balancer (2).

17. Underbody Skid Shield (2) » Install

18. Underbody Skid Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

19. Front Bumper Fascia Extension (4) » Install

20. Front Bumper Fascia Extension Bolt (3) @ Underbody Skid Shield » Install and tighten [2x] — Fastener Specifications

21. Front Bumper Fascia Extension Bolt (2) » Install and tighten [4x] — Fastener Specifications

22. Front Bumper Fascia Extension (1) » Install

23. Front Bumper Fascia Extension Bolt (2) » Install and tighten [8x] — Fastener Specifications

24. Front Bumper Fascia Air Deflector Bolt (1) » Install and tighten [10x] — Fastener Specifications

Engine Front Cover Replacement (L84 with WTX) — figure 47

Caution

Refer to Component Fastener Tightening Caution.

25. Oil Filter (1) » Install and tighten — Engine Oil and Oil Filter Replacement

26. Remove the support and lower the vehicle.

27. Water Pump Gasket (2) » Install NEW [2x]

28. Water Pump (1) » Install

29. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 29.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 29.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 29.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 29.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

30. Water Pump Housing Bolt (1) » Install and hand tighten [6x]

31. Water Pump Housing Bolt (1) » Tighten in sequence [6x] — Fastener Specifications

32. Engine Coolant Temperature Sensor Electrical Connector (1) » Connect

33. Radiator Inlet Hose (3) @ Water Pump » Install

34. Engine Coolant Air Bleed Hose (2) @ Water Pump » Install

35. Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

36. Radiator Outlet Hose (2) @ Water Pump » Install

37. Radiator Outlet Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

38. Heater Water Auxiliary Pump Hose (3) @ Water Pump » Install

39. Heater Inlet Hose (2) @ Water Pump » Install

40. Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

41. Air Conditioning Compressor (1) » Install

42. Air Conditioning Compressor Bolt (1) » Loosely install

43. Air Conditioning Compressor Stud (3) » Install and tighten — Fastener Specifications

44. Air Conditioning Compressor Bolt (1) » Tighten — Fastener Specifications

45. Air Conditioning Compressor Nut (2) » Install and tighten — Fastener Specifications

46. Generator (1) » Install

47. Generator Bolt (1) » Install and tighten — Fastener Specifications

48. Generator Bolt (2) » Install and tighten — Fastener Specifications

49. Engine Cooler Fan (1) @ Engine Radiator » Install

50. Engine Coolant Fan Bracket Bolt (1) » Install and tighten [2x] — Fastener Specifications

51. Transmission Fluid Cooler Pipe Clip (1) » Secure

52. Transmission Fluid Cooler Pipe Clip (2) » Install [2x]

53. Transmission Fluid Cooler Pipe Bolt (1) » Install and tighten — Fastener Specifications

54. Engine Oil Cooler Hose (1) @ Engine Radiator » Install [2x]

55. Engine Oil Cooler Pipe Bracket Bolt (3) » Install and tighten — Fastener Specifications

56. Engine Oil Cooler Retainer (2) » Install NEW [2x]

57. Position the wiring harness. (3)

58. Electrical Connector (1) » Connect

59. Wiring Harness Retainer (2) » Install [2x]

60. Position the wiring harness. (2)

61. Electrical Connector (3) » Connect

62. Wiring Harness Retainer (1) » Install [2x]

63. Radiator Inlet Hose (3) @ Engine Radiator » Install

64. Radiator Inlet Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

65. Radiator Inlet Hose Clip (2) » Install

66. Radiator Surge Tank Outlet Hose (3) » Move into position

67. Radiator Surge Tank Outlet Hose Clip (2) » Install [2x]

68. Engine Oil Cooler Hose Clip (1) » Secure

69. Starter Solenoid Cable (2) » Install

70. Battery Positive Cable Nut (1) » Install and tighten — Fastener Specifications

71. Electrical Connector (3) » Connect

Engine Front Cover Replacement (L84 with WTX) — figure 48

Note

The OEM replacement stretchy accessory drive auxiliary belt is packaged with a disposable installation tool and installation instructions.

72. Install the accessory drive auxiliary belt (1) following the instructions included with the accessory drive auxiliary belt.
73. Inspect the accessory drive auxiliary belt (1) for proper installation and alignment.

Engine Front Cover Replacement (L84 with WTX) — figure 49

74. Rotate the crankshaft balancer (1) an additional 360 degrees to ensure proper accessory drive auxiliary belt installation.

Engine Front Cover Replacement (L84 with WTX) — figure 50

75. Position the accessory drive primary belt (4) on the belt idler pulley (2), fan and water pump pulley (3), and generator (1).

Engine Front Cover Replacement (L84 with WTX) — figure 51

76. Install the EN-51767-2 Stretchy Belt Installer (1) onto the crankshaft balancer.

Engine Front Cover Replacement (L84 with WTX) — figure 52

77. Position the accessory drive primary belt (2) on the crankshaft balancer.
78. Slowly rotate the crankshaft balancer in a clockwise direction until the accessory drive primary belt (2) fully seats on the crankshaft balancer.
79. Remove the EN-51767-2 Stretchy Belt Installer (1) from the crankshaft balancer.

Engine Front Cover Replacement (L84 with WTX) — figure 53

80. Inspect the accessory drive primary belt (1) for proper installation and alignment.

Engine Front Cover Replacement (L84 with WTX) — figure 54

81. Rotate the crankshaft balancer (1) an additional 360 degrees to ensure proper accessory drive primary belt installation.

82. Air Cleaner Outlet Duct (3) » Install

83. Air Cleaner Outlet Duct Clamp (2) » Tighten [2x] — Fastener Specifications

84. Positive Crankcase Ventilation Fresh Air Tube (1) » Connect — Plastic Collar Quick Connect Fitting Service

85. Air Cleaner Outlet Duct Bracket Bolt (1) » Install and tighten — Fastener Specifications

86. Install engine wiring harness to air cleaner outlet duct bracket.

87. Fill the engine oil to the proper level with NEW engine oil. Approximate Fluid Capacities Adhesives, Fluids, Lubricants, and Sealers

88. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

89. Fill the cooling system. Cooling System Draining and Filling

90. Start the engine and check for coolant leaks.

91. Check for oil leaks.