Timing Cover: Service and Repair

Engine Front Cover

Material:

Removal
1. Remove the intake manifold.





2. NOTE: Remove the thermostat housing only if a new front cover is being installed.

Remove the 2 bolts and the thermostat housing.
^ Remove and discard the O-ring seal.





3. Disconnect the heater hose at the front cover.





4. Disconnect the lower radiator hose.





5. Remove the 3 bolts and position aside the power steering pump.





6. Remove the bolts and the accessory drive belt tensioner.





7. NOTE: Only one shown, others similar.

NOTE: Remove the accessory drive idler pulleys only if a new front cover is being installed.

Remove the bolts and the accessory drive idler pulleys.





8. NOTE: Remove the coolant pump pulley only if a new front cover is being installed.

Remove the 4 bolts and coolant pump pulley.





9. NOTE: Remove the coolant pump only if a new front cover is being installed.

Remove the 4 bolts and the coolant pump.
^ Remove and discard the O-ring seal.





10. Remove the nut and the battery cable bracket.
11. Remove the oil pump.





12. Remove the bolts and the front cover.

13. CAUTION: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the front cover gasket.

Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
^ Clean and inspect the sealing surfaces.

Installation





1. If removed, install the front cover crankcase dowels into the cylinder block.





2. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.

Install the guide studs.





3. Apply a bead of sealant at the seam where the crankcase and the lower crankcase meet.





4. Install a new engine front cover gasket.





5. Install the engine front cover and bolts.
^ Tighten to 24 Nm (18 ft. lbs.).

6. Install the oil pump.





7. Install the battery cable bracket and nut.
^ Tighten to 47 Nm (35 ft. lbs.).





8. NOTE: Install a new O-ring seal on the coolant pump.

If removed, install the coolant pump and bolts.
^ Tighten to 23 Nm (17 ft. lbs.).





9. If removed, install the coolant pump pulley and bolts.
^ Tighten to 31 Nm (23 ft. lbs.).





10. If removed, install the accessory drive idler pulleys and bolts.
^ Tighten to 47 Nm (35 ft. lbs.).





11. Install the accessory drive belt tensioner and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





12. Position back the power steering pump and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





13. Connect the lower radiator coolant hose.





14. Connect the heater hose at the front cover.





15. NOTE: Install a new O-ring seal.

If removed, install the thermostat housing and stud bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
16. Install the intake manifold.