2012 Jeep Wrangler JK Factory Service Manual 09 - Engine, 2.8L Diesel

COVER, Engine, Front

DESCRIPTION

DESCRIPTION

The front engine cover (2) incorporates the engine oil pump and vacuum pump. Neither of these components are serviceable, but only as a whole assembly.

REMOVAL

REMOVAL

Special Tools: Click to display a list of tools used in this procedure

  1. Disconnect the negative battery cable.

    2.  
  2. Drain the cooling system (Refer to 07 - Cooling - Standard Procedure) .

    3.  
  3. Remove the timing belt (Refer to 09 - Engine/Valve Timing/BELT, Timing - Removal) .

    NOTE:

    The crankshaft sprocket bolt is a left handed thread.


    4.  
  4. Remove bolt (1), and the crankshaft sprocket (2).

    5.  
  5. Disconnect the coolant tube hose at oil cooler and by fuel injection pump.

    6.  
  6. Remove bolts (2), and the coolant tube (1).

    7.  
  7. Disconnect the low pressure supply (1) and return (2) lines at injection pump.

    8.  
  8. Remove the fuel quantity solenoid (Refer to 14 - Fuel System/Fuel Delivery/SOLENOID, Fuel Quantity - Removal) .

    9.  
  9. Remove the high-pressure fuel tube (1) at rear of pump and fuel rail.

    10.  
  10. Remove the oil pump pickup tube (Refer to 09 - Engine/Lubrication/PICK-UP, Oil Pump - Removal) .


    11.  
  11. Disconnect the vacuum hose at vacuum pump.

    12.  
  12. Remove the eight bolts (1), and the front cover assembly (2).

    13.  
  13. If necessary, using Locking Tool VM.1055 (1) remove the injection pump sprocket nut (2).

    14.  
  14. If necessary, attach a Puller 1023 and remove sprocket from pump.

    15.  
  15. If necessary, remove nuts and the injection fuel pump.

    16.  
  16. If necessary, remove the vacuum pump check valve.

    17.  

INSTALLATION

INSTALLATION

Special Tools: Click to display a list of tools used in this procedure

  1. Clean all gasket mating surfaces.

    2.  
  2. If necessary, install the front crankshaft oil seal (Refer to 09 - Engine/Engine Block/SEAL, Crankshaft Oil - Installation) .

    3.  
  3. If necessary, transfer the vacuum pump check valve (1) and securely tighten.

    4.  
  4. If necessary, install the high pressure fuel pump. Tighten nuts to 24 N·m (18 ft. lbs.).

    5.  
  5. If necessary, using Locking Tool VM.1055 , install the high pressure fuel pump sprocket. Tighten nut (2) to 88 N·m (65 ft. lbs.).

    6.  
  6. Install the front cover gasket (3).

    7.  
  7. Install the front cover assembly (2) and tighten the eight bolts (1) finger tight.

    8.  
  8. Install the Tool, Front And Rear Seal VM.9990 (1) to align the front cover.

    9.  
  9. Using the tightening sequence shown, tighten bolts to 33 N·m (24 ft. lbs.).

    10.  
  10. Remove the Front and Rear Seal Tool 9990.

    11.  
  11. Install the oil pump pickup tube (Refer to 09 - Engine/Lubrication/PICK-UP, Oil Pump - Installation) .

    12.  
  12. Install the new high-pressure fuel tube (1) at rear of pump and fuel rail.

    • Tighten fuel tube nut at pump to 28 N·m (21 ft. lbs.).
    • Tighten fuel tube nut at fuel rail to 5 N·m (44 in. lbs.) plus an additional 75 degrees turn.

    13.  
  13. Install the fuel quantity solenoid (Refer to 14 - Fuel System/Fuel Delivery/SOLENOID, Fuel Quantity - Installation) .

    14.  
  14. Connect the low pressure supply (1) and return (2) lines at injection pump.

    15.  
  15. Install the coolant tube (1). Tighten bolts (2) to 15 N·m (133 in. lbs.).

    16.  
  16. Connect the coolant tube hose at oil cooler and by fuel injection pump.

    NOTE:

    The crankshaft sprocket bolt is a left handed thread.


    17.  
  17. Install the crankshaft sprocket (2). Tighten bolt to 100 N·m (74 ft. lbs.) plus an additional 120 degrees.

    18.  
  18. Install the timing belt (Refer to 09 - Engine/Valve Timing/BELT, Timing - Installation) .

    19.  
  19. Fill the cooling system (Refer to 07 - Cooling - Standard Procedure) .

    20.  
  20. Connect the negative battery cable.

    21.