Timing Cover: Service and Repair

Engine Front Cover

Material:

Accessory Drive Belt Tensioner, Power Steering Pump and Bracket Brace:

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 may cause engine failure.

1. Remove the coolant pump. For additional information, refer to Cooling System.
2. Remove the camshaft synchronizer. For additional information, refer to Computers and Control Systems.
3. Remove the crankshaft front seal.
4. Disconnect the crankshaft position (CKP) sensor electrical connector.
^ Detach the wiring harness retainers from the engine front cover stud bolts.
5. Drain the engine oil. Install the drain plug when finished.
^ Tighten to 26 Nm (19 lb-ft).
6. Remove the oil filter.
7. Remove the 2 oil pan-to-engine front cover bolts.
8. If equipped, remove the retaining nut and position the transmission coolant tube support bracket aside.
9. Remove the bolt and the accessory drive belt tensioner.

10. NOTE: Loosen the 2 upper bolts and the lower rear bolt first, then loosen the lower front bolt while sliding the power steering pump out.

Loosen the 4 power steering pump bolts and slide the power steering pump out approximately 25 mm (1 inch).
11. Remove the bolt and the A/C compressor and power steering pump bracket brace.

12. CAUTION: The cap screw is concealed by the oil pump housing. Failure to remove this retainer will result in damage to the engine front cover.

Remove the bolt and the stud bolts. Slide the engine front cover from the studs. Remove and discard the gasket.

13. NOTE: There are 2 different studs. Note the locations of the studs for installation reference.

Remove the 4 studs.

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 metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean and inspect the engine block and engine 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. Use silicone gasket remover and metal surface prep. Follow the directions on the packaging.
^ Using compressed air, remove any remaining foreign material from the engine block and front cover.
^ Remove the shop towels from the oil pan.
^ Remove the plugs or seals from the oil and coolant passages.
2. Apply thread sealant to the threads on the studs and the cap screw.
3. Install the engine front cover studs.
^ Tighten to 7 Nm (62 lb-in).

4. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure may cause future oil leakage.

Apply silicone gasket and sealant as shown.





5. Install the engine front cover gasket.

6. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure may cause future oil leakage.

Apply silicone gasket and sealant to the oil pan as shown.





7. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence. Failure to follow this instruction may cause future oil leaks.

Install the engine front cover and coolant pump.
^ Position the engine front cover and install the bolt, the stud bolts and the cap screw finger tight.
^ Position a new coolant pump gasket and the coolant pump and install the fasteners finger tight.
^ Tighten the fasteners in the sequence shown.
- Tighten capscrew No. 12 to 10 Nm (89 lb-in).
- Tighten all other fasteners to 28 Nm (21 lb-ft).





8. If equipped, position the transmission cooler tube bracket and install the nut.
^ Tighten to 20 Nm (15 lb-ft).
9. Install the accessory drive belt tensioner and the bolt.
^ Tighten to 55 Nm (41 lb-ft).
10. Install the 2 oil pan-to-engine front cover bolts.
^ Tighten to 10 Nm (89 lb-in).
11. Install a new oil filter.
^ Tighten to 16 Nm (12 lb-ft).
12. Connect the CKP sensor electrical connector.
^ Attach the wiring harness retainers to the engine front cover stud bolts.
13. Install the crankshaft front seal.
14. Install the camshaft synchronizer.
15. Position the coolant pump pulley and install the bolts.
^ Tighten to 25 Nm (18 lb-ft).





16. Position the A/C compressor and power steering pump pulley bracket brace and install the 2 bolts and 2 nuts.
^ Tighten the bolts to 48 Nm (35 lb-ft).
^ Tighten the nuts to 25 Nm (18 lb-ft).





17. NOTE: Slide the power steering pump in while tightening the front lower bolt, then tighten the rear lower and 2 upper bolts.

Tighten the power steering pump bolts.
^ Tighten to 25 Nm (18 lb-ft).
18. Install the accessory drive belt.
19. Install the cooling fan and fan shroud.
20. Fill the engine with clean engine oil.
21. Fill and bleed the cooling system.