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Front Cover: Removal

WARNING: This page is about a different car, the 2008 Dodge Sprinter. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Hood Opened
GC0066162Courtesy of CHRYSLER LLC
  1. Open the hood.
  2. Remove the engine cover.
    Fig 2: Remote Ground
    GC0066161Courtesy of CHRYSLER LLC
  3. Disconnect the remote battery ground.
  4. Raise and support the vehicle.
    Fig 3: Camshaft And Crankshaft Timing And TDC
    GC0066191Courtesy of CHRYSLER LLC
  5. Turn the engine to 40 degrees after Top Dead Center (1).
    Fig 4: Crankshaft Locking Tool
    GC0066245Courtesy of CHRYSLER LLC
  6. Install the crankshaft locking tool.
    Fig 5: Dipstick Tube Bolt
    GC0066253Courtesy of CHRYSLER LLC
  7. Remove the lower splash shield.
  8. Drain the coolant.
  9. Drain the engine oil.
  10. Remove the lower bolt to the engine oil dipstick tube.
    Fig 6: Grill Assembly
    GC0066187Courtesy of CHRYSLER LLC
  11. Lower the vehicle.
  12. Remove the grille (1).
    Fig 7: Fan Shroud Assembly
    GC0066192Courtesy of CHRYSLER LLC
  13. Remove the cooling module.
    Fig 8: PCM
    GC0066173Courtesy of CHRYSLER LLC
  14. Remove the PCM.
  15. Remove the engine harness.
    Fig 9: Air Pump And Vacuum Pump
    GC0066196Courtesy of CHRYSLER LLC
  16. Remove the upper oil dipstick tube bolt.
  17. Remove the oil dipstick and oil dipstick tube.
  18. Remove the intake manifold.
  19. Remove the air pump (5).
    Fig 10: Lower Oil Pan
    GC0066243Courtesy of CHRYSLER LLC
  20. Remove the lower oil pan (1) bolts.
  21. Remove the lower oil pan.
    Fig 11: Upper Oil Pan Bolts
    GC0066231Courtesy of CHRYSLER LLC
  22. Remove the upper oil pan bolts.
  23. Remove the upper oil pan.
    Fig 12: Accessory Drive Belt Bolt
    GC0066190Courtesy of CHRYSLER LLC
  24. Remove the accessory drive belt.
    Fig 13: Removing/Installing Thermostat
    GC0066222Courtesy of CHRYSLER LLC
  25. Remove the thermostat housing.
    Fig 14: Thermostat Gasket
    GC0066256Courtesy of CHRYSLER LLC
  26. Remove the thermostat gasket.
    Fig 15: Oil Filter/Cooler Housing, Idler Pulley, Vibration Damper Bolt And Crankshaft Damper
    GC0066246Courtesy of CHRYSLER LLC
  27. Remove the accessory drive belt tensioner assembly.
  28. Remove the oil filter/cooler housing (2).
  29. Remove the idler pulley (1).
  30. Remove the crankshaft damper bolt (4).
  31. Remove the crankshaft damper pulley (3).
    Fig 16: Water Pump Pulley And Bolts
    GC0066259Courtesy of CHRYSLER LLC
  32. Remove the water pump pulley bolts (5).
  33. Remove the water pump pulley (6).
    Fig 17: Water Pump Removed
    GC0066260Courtesy of CHRYSLER LLC
  34. Remove the water pump.
    Fig 18: Water Pump Gasket
    GC0066261Courtesy of CHRYSLER LLC
  35. Remove the water pump gasket.
    Fig 19: Left Front Cylinder Head Cover
    GC0066206Courtesy of CHRYSLER LLC
  36. Remove the left front cylinder head cover (1).
    Fig 20: Air Control Valve Bolts - Right
    GC0066197Courtesy of CHRYSLER LLC
  37. Remove the right side air control valve bolts.
  38. Remove the right side air control valve.
    Fig 21: Air Control Valve Gasket - Right
    GC0066215Courtesy of CHRYSLER LLC
  39. Remove the right air control valve gasket.
    Fig 22: Right Upper Front Cylinder Head Cove
    GC0066199Courtesy of CHRYSLER LLC
  40. Remove the upper right front cylinder head cover (1).
    Fig 23: Left ACV
    GC0066262Courtesy of CHRYSLER LLC
  41. Remove the left air control valve.
    Fig 24: Left ACV Gasket - Upper
    GC0066263Courtesy of CHRYSLER LLC
  42. Remove the left air control valve gasket.
    Fig 25: Left ACV Gasket - Lower
    GC0066264Courtesy of CHRYSLER LLC
  43. Remove the left air control valve adapter.
  44. Remove the left air control valve adapter gasket.
    Fig 26: Generator
    GC0066180Courtesy of CHRYSLER LLC
  45. Remove and position aside the power steering pump.
  46. Remove and position aside the AC compressor.
  47. Remove the generator.
    Fig 27: Ignition Coils And Left Cylinder Head Cover
    GC0066210Courtesy of CHRYSLER LLC
  48. Remove the left cylinder head cover (3).
  49. Remove the right cylinder head cover.
    Fig 28: Exploded View Of Timing Chain Tensioner
    GC0066201Courtesy of CHRYSLER LLC
  50. Remove the timing chain tensioner.
    Fig 29: Removing/Installing Variable Camshaft Gears
    GC0066202Courtesy of CHRYSLER LLC
  51. Install a drift into the camshaft to lock the split gears.
    Fig 30: Slide Rails
    GC0066247Courtesy of CHRYSLER LLC
  52. Remove the timing chain guide (2, 3) roll pins from the right cylinder head.
  53. Remove the center valve bolts (1, 4 ) from the camshafts.
    Fig 31: Installing Camshaft Tone Wheel
    GC0066212Courtesy of CHRYSLER LLC
    NOTE: The intake camshaft adjuster bolts are a L.H. thread. The exhaust camshaft bolts are a R.H thread.
  54. Remove the CMP plates.
    NOTE: Support the timing chain to prevent it from falling off the crankshaft or balance shaft.
  55. Remove the camshaft adjusters.
    Fig 32: Cylinder Head To Timing Case Bolts
    GC0066208Courtesy of CHRYSLER LLC
  56. Remove the cylinder head to front cover bolts (1) in the left cylinder head.
    Fig 33: Cylinder Head To Front Cover Bolts
    GC0066265Courtesy of CHRYSLER LLC
  57. Remove the cylinder head to front cover bolts (1) in the right cylinder head.
    Fig 34: Front Cover Removed
    GC0066234Courtesy of CHRYSLER LLC
    NOTE: The front cover bolts have several different sizes. Note the locations of each bolt.
  58. Remove the front cover bolts.
  59. Remove the front cover.
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