Timing Cover: Service and Repair

Engine Front Cover

Removal

CAUTION: During engine repair procedures cleanliness is extremely important, any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Disconnect the battery ground cable.
2. Drain the engine cooling system.
3. Remove the cowl extension panel.





4. Disconnect the degas bottle hose.
5. Remove the generator.





6. Remove the idler pulley.





7. Unclip the A/C wiring harness from the generator bracket brace.





8. Remove the bolts, generator bracket and the generator bracket brace as an assembly.





9. Disconnect the oil pressure sender electrical connector.





10. Disconnect the A/C compressor electrical connector.





11. Disconnect the Intake Manifold Runner Control (IMRC) actuator electrical connector.





12. Disconnect the camshaft position sensor and position the harness aside.
13. Remove the power steering pump.





14. Disconnect the hoses from the water pump outlet tube.
15. Remove the camshaft synchronizer.





16. Remove the power steering mounting bracket upper bolts.
17. Remove the crankshaft pulley.
18. Remove the Crankshaft Position (CKP) sensor.





19. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.





20. Remove the CMS mounting bracket.
21. Remove the belt tensioner.





22. Remove the power steering pump mounting bracket lower bolts and remove the bracket.





23. Remove and discard the oil filter.





24. Disconnect the radiator lower hose.





25. Remove the engine mount nuts.





26. Install the engine lifting eyes.





27. Install the engine lifting equipment and raise the engine 127 mm (5.08 inch).





28. Remove the four bolts and the water pump pulley.





29. Remove the water pump.
- Remove the five nuts.
- Remove the four bolts.
- Remove the water pump, lower tube and gasket as an assembly.





30. Remove the water pump-mounting studs.

31. CAUTION: The oil filter adapter hides the engine front cover lower left retainer. Failure to remove this retainer will result in damage to the engine front cover.





Remove the engine front cover and the oil filter adapter as an assembly.

32. Remove the timing chain and gears.

Installation

1. CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage.

CAUTION: Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces. Failure to follow these dictions will result in engine damage.

Clean and inspect the engine block and front cover as follows:
- Pack the exposed portion of the oil pan with
- clean shop towels.
- Plug the oil and coolant passages.
- Clean the gasket surfaces.
- Clean all surfaces requiring gasket sealant with metal surface cleaner.
- Using compressed air remove any remaining foreign material from the engine block and engine front cover.
- Remove the shop towels from the oil pan.
- Remove the plugs or seals from the oil and coolant passages.

2. Install the timing chain and gears.





3. Apply a small amount of silicone gasket and sealant as shown.





4. Install the engine front cover gasket and apply a small amount of silicone gasket and sealant as shown.

5. NOTE: Use pipe sealer on studs No. 4 and No. 6, and bolt No. 12.





Install the engine front cover.
- Install a 135.5 mm (5.42 inch) stud at location No. 5 and tighten to 7 Nm (62 inch lbs.).
- Install a 137 mm (5.48 inch) stud at locations No. 4, 6, 7 and 10, and tighten to 7 Nm (62 inch lbs.).
- Install the water pump with a new gasket.
- Tighten bolt No. 12 to 10 Nm (89 inch lbs.). All other nuts and bolts are to be tightened to 28 Nm (21 ft. lbs.).
- Tighten the nuts and bolts in the sequence shown.





6. Install the water pump pulley.





7. Lower the engine into position and remove the special tools.
8. Raise the vehicle on the hoist.





9. Install the engine mount nuts.





10. Connect the radiator lower hose.





11. Install the power steering pump mounting bracket and the lower retainers.





12. Install the belt tensioner.





13. Install the CMS mounting bracket.





14. Connect the CMS electrical connector.
15. Install the CKP sensor.
16. Install the crankshaft pulley.
17. Lower the hoist.





18. Install the power steering pump mounting bracket upper bolts.
19. Install the camshaft synchronizer.





20. Install the water pump outlet tube.





21. Connect the hoses to the water pump outlet tube.
22. Install the power steering pump.





23. Connect the camshaft position electrical connector.





24. Connect the IMRC actuator electrical connector.





25. Connect the A/C compressor electrical connector.





26. Connect the oil pressure sender electrical connector.





27. Install the generator bracket, bracket brace and bolts as an assembly.





28. Clip the A/C wiring harness to the generate bracket brace.





29. Install the idler pulley.
30. Install the generator.





31. Connect the degas bottle hose.
32. Raise the vehicle on the hoist.
33. Drain the engine oil.





34. Install a new oil filter.
35. Fill the engine with clean engine oil.
36. Fill the engine cooling system.
37. Connect the battery ground cable.