Timing Cover: Service and Repair

Engine Front Cover










Skid Plate










Accessory Drive Belt, Idler Pullies and Crankshaft Pulley










Power Steering Pump, Coolant Pump Pulley, Camshaft Position (CMP) Sensor and Electrical Connections










Engine Front Cover and Gaskets









Removal

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Remove the cooling fan.

3. Remove the LH valve cover. For additional information, refer to Valve Cover - LH Valve Cover - LH.

4. Remove the RH valve cover. For additional information, refer to Valve Cover - RH Valve Cover - RH.

5. Rotate the tensioner clockwise and remove the drive belt.





6. Disconnect the Engine Oil Pressure (EOP) sensor wiring harness retainer from the power steering pump stud bolt.

7. Remove the 2 bolts, the stud bolt and position the power steering pump assembly aside.

8. Disconnect the Camshaft Position (CMP) sensor electrical connector.

9. Remove the bolt and the CMP sensor.

10. Remove the nut and position the LH radio interference capacitor aside.

11. Remove the nut and position the RH radio interference capacitor aside.

12. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished.
- Tighten to 23 Nm (17 lb-ft).





13. Remove the pushpin and press the position retaining tab and rotate the lower cooling fan shroud upward until the position retainer tab locks into position.





14. NOTICE: This bolt is a torque-to-yield design and cannot be reused. Failure to follow this instruction may result in engine damage.

Using the Strap Wrench, remove the bolt and washer and discard the bolt.





15. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.





16. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft seal.





17. Remove the 4 coolant pump pulley bolts and the coolant pump pulley.

18. Remove the 3 bolts and the 3 accessory drive belt idler pulleys.

19. Remove the starter wiring harness bracket bolt at the starter.





20. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring harness support bracket.





21. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

22. Remove the nut and position aside the Power Steering Pressure (PSP) hose support bracket.





23. Remove the 4 oil pan bolts.

24. Remove the 9 bolts and the 6 stud bolts.





25. Remove the engine front cover from the front cover-to-cylinder block dowel.
- Remove and discard the engine front cover gaskets.





26. Remove the CKP sensor bolt and the CKP sensor.

27. NOTICE: 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 the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

- Inspect the mating surfaces.

Installation

1. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the CKP sensor and the CKP sensor bolt.

- Tighten to 10 Nm (89 lb-in).

2. NOTICE: 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 15 engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).










5. Loosely install the 4 bolts, then tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten an additional 60 degrees.





6. Connect the CKP sensor electrical connector.

7. Position the transmission cooler tube support bracket and the starter wiring harness support bracket and install the nut.
- Tighten to 10 Nm (89 lb-in).





8. Install the starter wiring harness bracket bolt at the starter.
- Tighten to 10 Nm (89 lb-in).





9. Install the 3 accessory drive belt idler pulleys and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

10. Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).

11. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.





12. Using the Crankshaft Front Oil Seal Installer, the Crankshaft Vibration Damper Installer and the Front Cover Oil Seal Installer, install the new crankshaft front seal into the engine front cover.





13. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. 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 in the crankshaft pulley.





14. Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation.





15. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.





16. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the Strap Wrench 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).





17. Position the PSP hose support bracket and install the nut.
- Tighten to 10 Nm (89 lb-in).





18. Position the RH radio interference capacitor and install the nut.
- Tighten to 25 Nm (18 lb-ft).

19. Position the LH radio interference capacitor and install the nut.
- Tighten to 25 Nm (18 lb-ft).

20. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the CMP sensor and the bolt.

- Tighten to 10 Nm (89 lb-in).

21. Connect the CMP sensor electrical connector.

22. Rotate the cooling fan shroud downward until the position retainer tab locks into position and install the pushpin.





23. Position the power steering pump assembly and install the 2 bolts and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).





24. Connect the EOP sensor wiring harness retainer to the power steering pump stud bolt.

25. Rotate the tensioner clockwise and install the drive belt.





26. Install the RH valve cover. For additional information, refer to Valve Cover - RH Valve Cover - RH.

27. Install the LH valve cover. For additional information, refer to Valve Cover - LH Valve Cover - LH.

28. Install the cooling fan.

29. Fill the engine with clean engine oil.

30. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.