Front Cover Gasket and Oil Pump

FRONT COVER GASKET AND OIL PUMP
Service repair no - 12.65.04 - Front Cover Gasket
Service repair no -12.60.26 - Oil Pump


Remove
1. Raise vehicle on four post lift.
2. Disconnect battery negative lead.
3. Raise lift.
4. Drain cooling system.
5. Remove oil sump.





6. Remove 2 bolts and nut securing oil pick up strainer.
7. Remove strainer and O-ring.
8. Remove oil filter.
9. Remove stand from under front cross member. Lower vehicle.
10. Remove crankshaft pulley.
11. Remove auxiliary drive belt tensioner.





12. Slacken bottom hose clip. Remove hose from water pump.
13. Disconnect oil cooler hoses from front cover. Plug hoses and connections.
14. Disconnect Lucar from oil pressure switch.





15. Disconnect multiplug from camshaft sensor.
16. Remove 9 bolts securing front cover.
17. Release cover from 2 dowels. Remove cover.
18. Remove gasket.
19. Remove seal from cover. Do not carry out further dismantling if component is removed for access only.





20. Remove 6 remaining bolts securing water pump to cover. Remove water pump and gasket.
21. Remove oil pressure switch.
22. Remove bolt securing camshaft sensor. Remove sensor from front cover.
23. Ensure mating faces of camshaft sensor and front cover are clean.
24. Refit sensor.
25. Refit sensor bolt. Tighten to 8 Nm (6 ft. lbs.)
26. Ensure thread of oil pressure switch is clean.
27. Refit switch to front cover. Tighten to 15 Nm (11 ft. lbs.)
28. Ensure water pump, its mating face, dowel and dowel hole are clean.
29. Refit water pump and new gasket.
30. Refit water pump bolts. Tighten to 22 Nm (16 ft. lbs.)


Refit
31. Ensure cover, its mating face, dowels and dowel holes are clean.
32. Ensure crankshaft and oil pump mating faces are clean.
33. Ensure oil seal register in cover is clean.





A- Early type seal
B- Later type seal - use as replacement for all covers

34. Lubricate new front cover oil seal with Shell Retinax LX grease ensuring that space between seal lips is filled with grease.

CAUTION: Do not use any other type of grease.





35. Using LRT-12-089, fit seal to cover.
36. Fit alignment tool LRT-12-090 to end of crankshaft.
37. Position front cover gasket on engine.





38. Position front cover on engine, align pump drive gear with key in crankshaft. Fit cover onto dowels.
39. Refit front cover bolts, tighten in sequence shown to 22 Nm (16 ft. lbs.).
40. Align camshaft sensor multiplug bracket. Refit bolts. Tighten to 22 Nm (16 ft. lbs.)
41. Connect camshaft sensor multiplug. Connect Lucar to oil pressure switch terminal.
42. Remove plugs from oil cooler hoses and cover.

CAUTION: Over tightening of oil cooler, hose unions can crack front cover.

43. Fit new O-ring seals, reconnect hoses to cover. Tighten to 15 Nm (11 ft. lbs.)
44. Reposition engine harness under auxiliary drive belt tensioner.
45. Refit tensioner and bolt. Tighten to 50 Nm (37 ft. lbs.)
46. Refit bottom hose to water pump. Tighten clip.
47. Fit engine oil filter.
48. Refit crankshaft pulley.
49. Ensure oil pick up strainer is clean.
50. Refit strainer and new O-ring to engine.
51. Refit strainer bolts. Tighten to 8 Nm (6 ft. lbs.)
52. Refit strainer nut to main bearing cap. Tighten to 25 Nm (18 ft. lbs.)
53. Refit sump.
54. Refill cooling system.
55. Reconnect battery negative lead.