Special Tools

J 37228 Seal Cutter

1. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement .
2. Remove the turbocharger coolant hoses/pipes - outlet. Refer to Turbocharger Coolant Hoses/Pipes Replacement .
3. Remove the upper oil pan. Refer to Upper Oil Pan Replacement .
4. Remove the cooling fan pulley. Refer to Cooling Fan Pulley Removal .
5. Remove the water pump. Refer to Water Pump Replacement .
6. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal .
7. Remove the engine oil fill tube bolts.
8. Remove the engine oil fill tube.



9. Remove the crankshaft position sensor bolt.
10. Remove the crankshaft position sensor.



11. Remove the engine front cover bolts.
12. Separate the engine front cover from the cylinder block using J 37228 .
13. Remove the engine front cover.

1. Install the relief valve O-ring to the engine front cover.
2. Lubricate the O-ring with engine oil.



3. Apply a 2-3 mm wide and 0.5-1.5 mm high bead of sealant to the mating surfaces of the engine front cover. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.



4. Install the engine front cover.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the engine front cover bolts.

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




6. Install a new O-ring to the crankshaft position sensor spacer.
7. Lubricate the O-ring with engine oil.
8. Install the crankshaft position sensor spacer.
9. Install the crankshaft position sensor spacer bolts.

Tighten
Tighten the crankshaft position sensor spacer bolts to 10 N·m (89 lb in).

10. Install a new O-ring to the crankshaft position sensor.
11. Lubricate the O-ring with engine oil.
12. Install the crankshaft position sensor.
13. Install the crankshaft position sensor bolt.

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

14. Install the engine oil fill tube. Refer to Oil Filler Tube Replacement .
15. Install the water pump. Refer to Water Pump Replacement .
16. Install the crankshaft balancer. Refer to Crankshaft Balancer Removal .
17. Install the cooling fan pulley. Refer to Cooling Fan Pulley Installation .
18. Install the upper oil pan. Refer to Upper Oil Pan Replacement .
19. Install the turbocharger coolant hoses/pipes - outlet. Refer to Turbocharger Coolant Hoses/Pipes Replacement .
20. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement .