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.

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 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 shown in Figure 1, from the water outlet tube.

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.

37. Remove the remaining front cover retainers.

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

39. Remove the camshaft position sensor drive gear. This will expose the camshaft and balance shaft timing marks.

40. Reinstall crankshaft damper bolt.





41. Rotate the crankshaft until the timing marks and the keyways are aligned. See Figure 5. This will position cylinder number 1 at TDC of the compression stroke, which is also required for camshaft synchronizer assembly installation.

42. Release tension on the timing chain as follows:





^ Using pliers, compress the timing chain tensioner. See Figure 6.

^ Insert a pick through the tensioner housing and into the tensioner. See Figure 6.

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.

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

44. Remove the timing chain tensioner.