Front Cover, Timing Chain and Sprockets - Installation
FRONT COVER, TIMING CHAIN AND SPROCKETS - INSTALLATION
1. Clean and inspect all parts before installation.
CAUTION: DO NOT USE CARBURETOR CLEANER OR ANY OTHER SOLVENT THAT WILL LEAVE A HYDROCARBON RESIDUE ON THE PARTS WHICH WILL PREVENT THE RTV FROM BONDING TO THE ENGINE/OIL PAN. FAILURE TO COMPLETELY CLEAN THE SURFACE PRIOR TO THE USE OF THE BRAKE CLEANER OR USE OF THE INCORRECT SOLVENT COULD RESULT IN A REPEAT REPAIR.
2. Clean the cylinder block and front cover of gasket material and dirt, then blow out any fluid in the front cover bolt holes.
3. Slide both sprockets and timing chain onto the camshaft and crankshaft with timing marks aligned. Install camshaft bolt and washer. Tighten to 41-56 lb-ft (55-75 N-m).
4. Install timing chain tensioner. Tighten to 8-12 N-m.
5. Oil the timing chain, sprockets and tensioner after installation.
6. Install new front cover gasket (F13Z-6020-A).
a. Position gasket onto front cover, front oil seal removed.
b. Position front cover on engine loosely.
c. Install Front Cover Aligner (T84P-6019-C) onto crankshaft.
d. Ensure that crank key is aligned with keyway in tool.
NOTE: THE ALIGNER TOOL IS REQUIRED BECAUSE THE FRONT COVER BOLTS ARE NOT DESIGNED TO ALIGN THE FRONT COVER SEAL WITH RESPECT TO THE CRANKSHAFT.
7. Use thread sealant (E2AZ-19562-B) on the front cover lower bolts only. Tighten to 6-9 lb-ft (8-12 N-m). Remove the front cover aligner.
8. Replace the front cover seal with a new one (E83Z-6700-A). Install seal using a Pinion Oil Seal Replacer (T83T-4676-A).
9. Lubricate the hub of the crankshaft damper with multi-purpose grease (D0AZ-19584-AA, ESR-M1C159-A) or equivalent to prevent damage to the seal during installation and initial engine start. Install crankshaft damper and bolt.
10. Remove and clean the oil pick-up tube and screen assembly. After cleaning, install the pick-up and screen assembly.
11. Obtain a tube of the new grade RTV (F1AZ-19562-A) and check the expiration date before using.
WARNING: USE ADEOUATE VENTILATION WHEN APPLYING RTV SEALER.
Figure 3:
Figure 4:
12. Apply enough RTV (F1AZ-19562-A) in the oil pan to completely fill the oil pan groove, regardless of the groove size or configuration, Figures 3 and 4.
^ Have a bead about 0.2" (5 mm) wide by 0.25" (6 mm) high, above the pan surfaces, in both front and rear half-rounds, Figures 2 and 3.
^ Have a bead about 0.2" (5 mm) wide by 0.15" (4 mm) high, above the oil pan surfaces, along the rails, Figures 2 and 3.
NOTE: BE SURE THAT THE GROOVE IS COMPLETELY FILLED WITH RTV. MAKE CERTAIN THAT NO AIR IS TRAPPED IN THE GROOVE BECAUSE A BLOW OUT OF THE RTV MAY OCCUR WHEN THE ENGINE IS HEATED UP DURING NORMAL ENGINE OPERATIONS.
^ Have the nozzle of the RTV tube slightly above the oil pan groove.
^ Apply enough RTV to build up the bead above the oil pan surface before moving the nozzle along the groove.
^ Do not lay the RTV nozzle on top of the groove because this may leave air pockets, especially in oil pans with deep grooves, Figure 4.
CAUTION: APPLYING RTV IN EXCESS OF THE SPECIFIED AMOUNT WILL NOT IMPROVE THE SEALING OF THE OIL PAN. IT COULD CAUSE THE OIL PICK-UP SCREEN TO BECOME PLUGGED WITH PIECES OF RTV.
13. Immediately, within 5 minutes of applying the RTV to the oil pan, install the oil pan against the cylinder block to prevent the RTV from skinning over. Tighten the oil pan bolts as follows:
a. Tighten the oil pan to transaxle bolts to 30-39 lb-ft (40-54 N-m).
b. Loosen the oil pan to transaxle bolts 1/2 turn.
c. Tighten the oil pan flange bolts to 15-22 lb-ft (20-30 N-m). Start in the center of the oil pan and work to the rear of the engine. Then, tighten the bolts from the center to the front of the engine.
d. Tighten the oil pan to transaxle bolts to 30-39 lb-ft (40-54 N-m).
14. Install the bracket from the air conditioning compressor line above the oil pan.
15. Install the bracket at the block and install the water pump inlet tube assembly.
16. Install the starter motor.
17. Install the thermactor (MTA) tubes and connect the rubber hose at the check valve.
18. Install two (2) bolts that secure the air conditioning compressor line and the water pump inlet tube to the pan bottom.
19. Lower the vehicle.
20. Raise the engine assembly.
21. Raise the vehicle.
22. Install the retaining bolts to the stabilizer bar bracket.
23. Lower the vehicle.
24. Install the top front cover bolts. Tighten to 8-12 N-m.
25. Install idler pulley bracket.
26. Install idler pulley.
27. Install engine mounts.
28. Install belt tensioner.
29. Remove engine support bar.
30. Install fuel line shield.
31. Install drive belt.
32. Connect battery ground cable.
33. Install coolant.
34. Install engine oil.
CAUTION: DO NOT ADD ENGINE OIL UNTIL ONE HOUR AFTER THE OIL PAN BOLTS HAVE BEEN TIGHTENED. THIS ALLOWS THE OUTSIDE LAYER OF THE RTV TO SKIN OVER PRIOR TO COMING IN CONTACT WITH THE ENGINE OIL.