Timing Cover: Service and Repair
Engine Front CoverSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material:
Accessory Drive Belt, Idler Pullies and Crankshaft Pulley:
Power Steering Pump, Coolant Pump Pulley and Electrical Connections (Part 1):
Power Steering Pump, Coolant Pump Pulley and Electrical Connections (Part 2):
Engine Front Cover and Gaskets (Part 1):
Engine Front Cover and Gaskets (Part 2):
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Drain the engine oil.
3. Remove the cooling fan. For additional information, refer to Cooling System.
4. Remove the RH valve cover.
5. Remove the LH valve cover.
6. Rotate the tensioner clockwise and remove the drive belt.
7. CAUTION: This bolt is torque-to-yield and cannot be reused. Failure to follow these instructions may result in engine damage.
Using the special tool, remove the bolt and washer and discard the bolt.
8. Using the special tool, remove the crankshaft pulley.
9. Using the special tool, remove and discard the crankshaft front seal.
10. Remove the 4 coolant pump pulley bolts and the coolant pump pulley.
11. Remove the 3 bolts and the 3 accessory drive belt idler pulleys.
12. Using the special tool, remove the power steering pump pulley.
13. Disconnect the power steering pressure tube.
^ Drain the power steering fluid into a suitable container.
14. Remove the nut and position aside the power steering pressure tube.
15. Remove the bolts and position the power steering pump assembly aside.
16. Disconnect the camshaft position (CMP) sensor electrical connector.
17. Remove the (CMP) sensor bolt and the CMP sensor.
18. Remove the nut and position the LH radio interference capacitor aside.
19. Remove the nut and the upper radiator hose bracket.
20. Remove the nut and position the RH radio interference capacitor aside.
21. Disconnect the crankshaft position (CKP) sensor electrical connector.
22. Remove the 4 oil pan bolts.
23. Remove the nut and the A/C manifold and tube assembly support bracket.
24. If equipped, remove the nut and the transmission cooler tube support bracket.
25. Remove the bolts and the studs.
26. 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.
Remove the engine front cover from the front cover-to-cylinder block dowel.
^ Remove the engine front cover gaskets.
^ Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
^ Inspect the mating surfaces.
27. Remove the CKP sensor bolt and the CKP sensor.
Installation
1. Install the CKP sensor and the CKP sensor bolt.
^ Tighten to 10 Nm (89 lb-in).
2. 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.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
3. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder block dowel and loosely install the bolts.
4. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
5. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten an additional 60 degrees.
6. If equipped, install the transmission cooler tube support bracket and nut.
^ Tighten to 10 Nm (89 lb-in).
7. Install the A/C manifold and tube assembly support bracket and nut.
^ Tighten to 10 Nm (89 lb-in).
8. Connect the CKP sensor electrical connector.
9. Position the RH radio interference capacitor and install the nut.
^ Tighten to 25 Nm (18 lb-ft).
10. Position the upper radiator hose bracket and install the nut.
^ Tighten to 10 Nm (89 lb-in).
11. Position the LH radio interference capacitor and install the nut.
^ Tighten to 25 Nm (18 lb-ft).
12. Install the CMP sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).
13. Connect the CMP sensor electrical connector.
14. Position the power steering pump and install the bolts.
^ Tighten to 25 Nm (18 lb-ft).
15. Using the special tool, install a new O-ring seal on the pressure line fitting.
16. Connect the power steering pressure tube.
^ Tighten to 65 Nm (48 lb-ft).
17. Position the power steering pressure tube support bracket and install the nut.
^ Tighten to 12 Nm (9 lb-ft).
18. NOTE: If the pulley has been removed and installed twice, install a new power steering pump pulley.
Using the special tool, install the power steering pump pulley.
^ Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a new pulley. If there is one paint mark or none at all, use a pencil to mark the web area of the pulley near the hub.
19. Install the 3 accessory drive belt idler pulleys and the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).
20. Install the coolant pump pulley and the 4 bolts.
^ Tighten to 25 Nm (18 lb-ft).
21. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
22. Using the special tools, install a new crankshaft front seal.
23. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
24. Using the special tool, install the crankshaft pulley.
25. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
^ Stage 1: Tighten to 90 Nm (66 lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 lb-ft).
26. Rotate the tensioner clockwise and install the drive belt.
27. Install the LH valve cover.
28. Install the RH valve cover.
29. Install the cooling fan.
30. Fill the engine with clean engine oil.