Front Cover Removal

1. Install memory saver then disconnect the battery negative cable.

2. Raise and support the vehicle.

3. Completely drain the radiator of coolant. Do not drain the engine oil at this time.

4. Disconnect the knock sensor electrical connector. Route the wiring to the front of the engine.

5. Disconnect the crankshaft position sensor electrical connector.

6. Disconnect the oil pressure sender electrical connector.

7. Lower the vehicle.

8. Remove the jack handle.

9. Remove the front air deflector.

10. Remove the upper radiator hose.

11. Remove the engine cooling fan and the fan shroud.

12. Remove the drive belt.

13. Disconnect the camshaft position (CMP) sensor electrical connector.

14. Detach the engine wiring harness pushpin from the water outlet tube flange.

15. Route the front of the engine wiring harness away from the engine front cover.

16. Disconnect the throttle position sensor electrical connector.

17. Remove the vacuum line from the EGR valve.

18. Disconnect the heater hose from the fitting on the lower intake manifold, next to the thermostat housing.

19. Disconnect the EGR tube from the EGR valve only.





20. Disconnect the three (3) coolant hoses from the water outlet tube. See Figure 1.

21. Remove the water outlet tube retaining bolt.





22. Reposition the water outlet tube to access the remaining coolant hose. See Figure 2.

23. Remove the coolant hose from the water outlet tube, then remove the water outlet tube.

24. Remove the camshaft position sensor.





25. Remove the camshaft synchronizer assembly. See Figure 3.

26. Using Power Steering Pump Pulley Remover (T69L-10300-B), remove the power steering pump pulley.





27. Remove the power steering pump bracket. See Figure 4.

28. Remove the top drive belt idler pulley. See Figure 4.

29. Remove the drive belt tensioner. See Figure 4.

30. Disconnect the lower radiator hose from the water pump.

31. Remove the water pump pulley, then the water pump.

32. Remove the crankshaft pulley.

33. Using Crankshaft Damper Remover (T58P-6316-D) and Vibration Damper Remover Adapter (T82L-6316-B), remove the crankshaft damper.

CAUTION
Do not damage the front cover or the crankshaft, as possible engine oil leakage may occur.

34. Remove the crankshaft front seal from the engine front cover.

35. Install double nuts on the water pump studs, then remove the studs.

36. Remove the oil filter and discard. Do not drain the engine oil at this time. It will be done during the Front Cover Installation procedure.

37. Remove the remaining front cover retainers.

CAUTION
Carefully cut the RTV sealant at the bottom of the front cover with a utility knife and pry carefully on the sides of the cover to avoid cracking the cover.

38. Remove the front cover and the oil filter adapter as an assembly.





39. Prevent debris from entering the block, front cover, oil pan, and oil and coolant passages by taping, plugging, or sealing the passages prior to removing old gasket material. Immediately put shop towels in the front of the oil pan once the front cover is removed and plug the two oil passages in the block. See Figure 5. The passages can be plugged with plastic plugs such as power steering hose plugs or tape. These same two passages must be plugged in the front cover before attempting to remove the old gasket. If debris does enter these passages, it will cause engine damage. The area around these passages should be hand scraped to avoid any possibility of contamination. It is important to prevent contamination from occurring. Debris cannot be cleaned out without engine and front cover disassembly.

NOTE:
Leave rags and plugs in place when cleaning gasket particles off the front of the block. Remember to carefully remove the plugs and rags from the passages and oil pan before installing the new gasket. Use care when removing so that contamination does not enter the engine.

40. Remove the camshaft Position sensor drive gear. This will expose the camshaft and balance shaft timing marks.

41. Reinstall crankshaft damper bolt.





42. Rotate the crankshaft until the timing marks and the keyways are aligned. See Figure 6. This will Position cylinder number 1 at TDC of the compression stroke, which is also required for camshaft synchronizer assembly installation.

43. Release tension on the timing chain as follows:





^ Using pliers, compress the timing chain tensioner. See Figure 7.

^ Insert a pick through the tensioner housing and into the tensioner. See Figure 7.

NOTE:
The timing chain and sprockets are being removed to keep debris from collecting on these parts and to allow more room for cleaning the block front cover mating surface.

NOTE:
Do not remove the balance shaft sprocket or the balance shaft.

44. Remove the camshaft sprocket, crankshaft sprocket and the timing chain as an assembly.

45. Remove the timing chain tensioner.