Timing Cover: Service and Repair
ENGINE FRONT COVER - 2.3L REMOVAL/INSTALLATION
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.
Caution
^ Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the accessory drive belt and idler pulleys.
3. Remove the crankshaft pulley.
4. Remove the engine mount.
5. Using the special tool, remove the crankshaft front oil seal.
Caution
^ Use care not to damage the engine front cover or the crankshaft when removing the seal.
6. Remove the 3 bolts and the coolant pump pulley.
7. Remove the 3 bolts and the accessory drive belt idler pulley and bracket.
8. Disconnect the crankshaft position (CKP) sensor electrical connector.
9. Remove and discard the CKP sensor.
Note
^ Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed, using the alignment tool supplied with the new part.
10. Remove the bolts and the engine front cover.
Installation
1. Clean and inspect the mounting surfaces of the engine and the front cover.
Caution
^ Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
Note
^ The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
^ Tighten the 8 mm bolts to 10 N-m (1.0 kgf-m, 89 in-lbf).
^ Tighten the 13 mm bolts to 48 N-m (4.9 kgf-m, 35 ft-lbf).
4. Install the accessory drive belt idler pulley and bracket and the 3 bolts.
^ Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
5. Install the water pump pulley and bolts.
^ Tighten to 20 N-m (2.0 kgf-m, 15 ft-lbf).
6. Using the special tool, install the crankshaft front oil seal.
Note
^ Remove the through-bolt from the special tool.
Note
^ Lubricate the oil seal with clean engine oil.
7. Install the engine mount.
8. Install the crankshaft pulley.
9. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
^ Rotate the pulley as necessary to align the bolt holes.
Caution
^ Only hand-tighten the bolt or damage to the front cover can occur.
10. Install a new CKP sensor and the 2 bolts.
^ Do not tighten the bolts at this time.
Note
^ Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
11. Adjust the CKP sensor with the alignment tool.
^ Tighten the 2 CKP bolts to 7 N-m (0.7 kgf-m, 62 in-lbf).
Note
^ The crankshaft position (CKP) sensor alignment tool is supplied with the new sensor and is not available separately.
12. Connect the CKP sensor electrical connector.
13. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
14. Install the accessory drive belt and idler pulleys.