Timing Cover: Service and Repair

REMOVAL
1. Disconnect negative battery terminal and move out of the way.
2. Remove air cleaner fresh air tube.
3. Drain cooling system and crankcase.
4. Remove cooling fan.
5. Loosen water pump hub bolts.
6. Loosen and remove accessory drive belts.
7. Remove water pump pulley. Remove auxiliary heater coolant tube (if equipped) retaining nut from water pump stud bolt. Remove lower tube retaining bracket bolt from cylinder block. Move assembly out of way.
8. Remove alternator adjusting arm and the brace to throttle body attaching stud. Move alternator assembly out of the way.
9. Remove four air conditioner compressor bolts. Wire tie compressor out of the way. Remove air conditioner bracket.
10. Remove crankshaft pulley and damper.
11. Remove water pump if required.

NOTE: Timing cover may be removed with water pump intact. To perform this operation, do not remove bolts numbered 11 through 15 on the Front Cover, Water Pump Fastener Chart.

12. Disconnect lower radiator hose and heater hose.
13. Remove oil pan assembly and discard old gasket. Disconnect oil level sensor (if equipped) before pan removal.
14. Remove timing cover to cylinder block attaching bolts.
15. Carefully remove timing cover from cylinder block. Discard old gasket.


INSTALLATION
1. Clean cylinder block mating surface.
2. Clean timing cover gasket surface carefully.

CAUTION: Gouges in aluminum timing cover will cause gasket to leak.

3. Replace crankshaft seal.

Front Cover Assembly:

4. Align new timing cover gasket to cylinder block dowel pins.

Front Cover, Water Pump Torque Chart:

5. Install timing cover and attaching bolts. Note bolts that require pipe sealant on the chart. Tighten bolt numbers 1 through 10 to 25 Nm (19 ft lb) and bolt numbers 11 through 15 to 10 Nm (7 ft lb).

NOTE: Lightly oil all bolt threads except for those requiring special sealant.

6. Install oil pan and new gasket. Tighten attaching bolts to 12 Nm (9 ft lb).
7. Install water pump, if removed.
8. Install crankshaft damper, attaching bolt and pulley.
9. Install lower radiator hose and heater hose.
10. Install air conditioner bracket, compressor and brace.
11. Install alternator assembly, bracket, oil fill tube support and throttle body brace. Install auxiliary heater coolant tube bracket to water pump stud bolt. Hand-tighten retaining nut. Install lower tube bracket bolt to cylinder block and tighten.
12. Install water pump pulley and accessory drive belts. Tension belts.
13. Install cooling fan and shroud.
14. Fill and bleed cooling system with proper coolant mixture.

CAUTION: This engine has aluminum components and requires a special corrosion inhibited coolant formulation to avoid radiator damage.

15. Fill crankcase with specified amount and viscosity of engine oil.
16. Connect negative battery terminal.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

17. Install air cleaner fresh air hose.
18. Run engine and check for oil and coolant leaks.