Timing Cover: Service and Repair

Engine Front Cover

Material:

Material

Removal
1. Disconnect the battery ground cable.






2. NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley 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 the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage can occur.

Remove the crankshaft pulley. Service and Repair





3. Disconnect the Crankshaft Position (CKP) sensor electrical connector and the wiring harness pin-type retainers.






4. NOTE: A new CKP sensor must be installed whenever the old sensor is removed.

Remove and discard the crankshaft position sensor.





5. Remove the belt tensioner.
6. Remove the water pump pulley.





7. Disconnect the Power Steering Pressure (PSP) switch electrical connector.





8. Remove the bolt and position the power steering pump aside.






9. NOTE: This step is needed only if a new front cover is being installed.

Using a three jaw puller, remove the fan drive pulley.






10. CAUTION: There is one bolt behind the cooling fan drive pulley. This bolt can be accessed by lining up one of the holes in the pulley with the bolt.

Remove the bolts and the engine front cover.

Installation






1. NOTE: This step is needed only if a new front cover is being installed.

Install the fan drive pulley, using a nut and bolt with flat washers.

2. 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.

Clean and inspect the mounting surfaces of the engine and the front cover.






3. NOTE: The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.

Apply a 2.5 mm (0.1 inch) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.1 inch) bead of silicone gasket and sealant to the front cover.





4. Install the front cover. Tighten the bolts in the sequence shown, to the following specifications:
^ Tighten the 8 mm bolts to 10 Nm (89 inch lbs.).
^ Tighten the 10 mm bolts to 25 Nm (18 ft. lbs.).
^ Tighten the 13 mm bolts to 48 Nm (35 ft. lbs.).





5. Position the power steering pump and install the lower retaining bolt.





6. Connect the Power Steering Pressure (PSP) switch electrical connector.





7. Install the water pump pulley.





8. Install the belt tensioner.

9. Install the crankshaft pulley. Service and Repair

10. NOTICE: Only hand tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.

Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.









11. Install a new Crankshaft Position (CKP) sensor. Do not tighten the bolts at this time.





12. Adjust the CKP with the alignment tool supplied with the new sensor and tighten the CKP mounting bolt.

13. Remove the 6 mm (0.23 in ) bolt.





14. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
15. Connect the battery ground cable.