Front Housing and Accessory Drive - Remove and Install


Front Housing  

Removal Procedure

Tool Part
A - 3 Bond
B - Guide Stud (M8 by 70 mm)
C – Setscrews (M10 by 50 mm)
D - Straight Edge

Remove:
- the fan. If necessary, remove the alternator.
- the front pulley. Drain the coolant into a suitable container for storage or disposal.


- the two setscrews (1) that secure the bypass tube (2) to the front housing (3).
- the bypass tube (2) from the cylinder head.
- the O-rings (4) and (5) from the bypass tube (2). Discard the O-rings.


- the setscrews (7), (8) and (9) from the front housing (3). The setscrews are three different lengths. Note the positions of the different setscrews.
- the front housing (3) from the cylinder block.
- the joint (6). Discard the joint.


- the thrust washer (10) from the cylinder block.

Installation Procedure

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Ensure that the front housing is clean and free from damage. If necessary, replace the front housing.
Install:
- blanking plugs to a new front housing. Use Tooling (A) to seal all D-plugs. Check the condition of the crankshaft front seal. If the front seal is damaged, remove the front seal from the front housing. Clean all the mating surfaces of the cylinder block.
- the thrust washer (10) into the recess in the cylinder block.


- Tooling (B) to the cylinder block. Refer to Illustration. Align a new joint (6) with Tooling (B). Install the joint to the cylinder block. Ensure that two circular tabs (X) on the joint are engaged in the two holes (Y) in the cylinder block.


- Tooling (C) to the cylinder block.
- the front housing over Tooling (B) and Tooling (C) onto the cylinder block.

(7) M8 by 20 mm
(8) M8 by 35 mm
(9) M8 by 25 mm

- the four setscrews (9) to the front housing (3) finger tight. Remove Tooling (B). Loosely install the setscrews (7) and (8). Refer to Illustration for the correct position of the setscrews. Align the bottom face of the front housing (3) to the lower machined face of the cylinder block. Use a Tooling and a feeler gauge in order to check the alignment between the front housing and the cylinder block. Refer to Illustration


Tighten the setscrews (6), (7) and (8) in the sequence that is shown in illustration to a torque of 28 N·m (20 lb ft). Ensure that the housing and the cylinder block are correctly aligned. Remove Tooling (C) from the cylinder block. If necessary, install a new crankshaft front seal.


- two new O-ring seals (4) and (5) to the bypass tube (1). Use Tooling in order to lubricate the O-ring seals.
- the bypass tube (2) to the cylinder head. Install the two setscrews (1). Tighten the setscrews to a torque of 22 N·m (16 lb ft). Fill the cooling system with coolant.
- the fuel injection pump.
- the timing gears.  If the engine has an accessory drive, install the accessory drive.
- the engine oil pan.
- the front pulley. If necessary, install the alternator.
- the fan.



Accessory Drive

Removal Procedure

Remove:
- the M10 Allen head screw (1) from the accessory drive housing (8). 
- the five M8 Allen head screws (6) from the accessory drive housing (8).
- the accessory drive housing (8) from the front housing.
- the circlip (2) from the accessory drive housing (8). Place the accessory drive housing (8) onto a suitable support. Press the assembly of the gear (4) and the bearings (3) and (5) out of the accessory drive housing (8). Use a suitable puller in order to remove the bearings (3) and (5) from the gear (4).
- the O-ring seal (7) from the accessory drive housing (8). Discard the O-ring seal.


Installation Procedure

Inspect the condition of the teeth and the splines of the gear (4) for wear or damage. Inspect the bearings (3) and (5), the circlip (2), and the front housing for wear or damage. Replace any components that are worn or
damaged. Apply a small continuous bead of Tooling to the inner surface (X) of the bearing (5). Place the gear shaft on a suitable support. Press on the inner race of the bearing (5) until the bearing (5) is against the shoulder of the gear (4). Remove any excess sealant.
Apply a small continuous bead of Tooling to the inner surface (Z) of the bearing (3). Place the front face of the inner race of the bearing (3) onto a suitable support. Press the shaft of the gear (4) into the bearing (3) until the shoulder of the gear is against the bearing. Remove any excess sealant.
Apply a small continuous bead of Tooling to the outer surface (Y) of the bearing (5). Place the accessory drive housing (8) on a suitable support. Press the assembly of the gear (4) and the bearings (3) and (5) into the accessory drive housing . Ensure that the bearing (5) is against the front face of the recess in the accessory drive housing (8). Remove any excess sealant.
Install the circlip (2) into the groove in the accessory drive housing (8). Ensure that the circlip (2) is correctly positioned in the groove.
Lightly lubricate a new O-ring seal (7) with Tooling and install the O-ring seal into the groove in the accessory drive housing (8). Inspect the bore in the front housing (not shown) for damage. If necessary, replace the front housing.
Lightly lubricate the bearing (3), the bearing (5), and the gear (4) with clean engine lubricating oil. Install the assembly of the accessory drive to the front housing. Apply Tooling to the Allen head screws (1) and (6). Install the five M8 Allen head screws (6) to the accessory drive housing (8). Install the M10 Allen head screw (1) to the accessory drive housing (8). Tighten the Allen head screws to a torque of 22 N·m (16 lb ft). Ensure that there is tactile backlash between the idler gear and the accessory drive gear.