Timing Cover: Service and Repair

TIMING CHAIN COVER
REMOVAL
1) Perform the fuel pressure relief procedure.
2) Disconnect negative cable from battery.
3) Evacuate air conditioning.
4) Drain cooling system.
5) Remove the air cleaner assembly.





6) Loosen the water pump pulley bolts (Fig. 175).
7) Remove the accessory drive belt and belt tensioner.
8) Remove power steering pump fasteners and set pump aside (Fig. 175).
9) Remove the generator.
10) Disconnect the air conditioning compressor clutch electrical connector and suction discharge hoses (Fig. 175).
11) Remove the oil level indicator tube.
12) Raise vehicle on hoist.
13) Drain engine oil.
14) Remove right wheel and inner splash shield.
15) Remove oil pan.





16) Disconnect the lower radiator hose and oil cooler hose at the coolant cross over pipe (Fig. 176).
17) Separate the power steering lines from the A/C bracket and bracket at cradle.
18) Separate the air conditioning compressor from the engine and set aside.
19) Remove crankshaft vibration damper using special tool #8454 and insert #8450.
20) Remove the coolant cross over pipe fasteners and pipe (Fig. 176).





21) Remove accessible lower timing cover fasteners through the wheel well (Fig. 174).





22) Remove camshaft position sensor from timing chain cover (Fig. 177).
23) Remove the water pump, for cover removal clearance.
24) Support the engine with a floor jack and remove the upper engine mount assembly.
25) Remove the timing chain cover fasteners and remove timing chain cover (Fig. 174).

INSTALLATION

CAUTION: Crankshaft oil seal must be removed to insure correct oil pump engagement.

1) Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs.

NOTE: DO NOT USE SEALER ON COVER GASKET





2) Position new gasket on timing cover (Fig. 178). Adhere new gasket to chain case cover, making sure that the lower edge of the gasket is 0.5 mm (0.020 inch) beyond the lower edge of the cover.
3) Rotate crankshaft so that the oil pump drive flats are in the vertical position.
4) Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats (Fig. 178).

CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.

5) Install timing cover (Fig. 178).





6) Install timing chain cover bolts. Tighten M8 bolts to 27 Nm (20 ft. lbs.) and M10 bolts to 54 Nm (40 ft. lbs.) (Fig. 179).
7) Install crankshaft front oil seal.
8) Install crankshaft vibration damper.





9) Install the coolant cross over pipe (Fig. 180).
10) Install A/C compressor.
11) Position and install the power steering line hold downs at the cradle and A/C bracket.
12) Connect the coolant hoses to the coolant cross over pipe.
13) Install the inner fender splash shield.
14) Install oil pump pick-up tube with new O-ring. Tighten attaching bolt to 28 Nm (250 inch lbs.).
15) Install the oil pan.
16) Lower the vehicle.
17) Install water pump and pulley.
18) Install camshaft position sensor.





19) Connect the A/C electrical connector and the suction, discharge hoses (Fig. 181).
20) Install the oil level indicator tube.
21) Install the generator (Fig. 181).
22) Install the power steering pump (Fig. 181).
23) Install the idler pulley (Fig. 181).
24) Install the accessory drive belt (Fig. 181)
25) Install the upper engine mount.
26) Fill crankcase with engine oil to proper level.
27) Fill cooling system.
28) Evacuate and recharge A/C.
29) Check and refill all fluid levels.
30) Connect negative cable to battery.