Timing Cover: Service and Repair

Engine Front Cover

Special Tool(s):

Material:

Removal

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.

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.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Loosen the 3 coolant pump pulley bolts.
3. Remove the accessory drive belt and idler pulley.
4. Remove the crankshaft pulley.
5. If equipped, remove the 7 screws and the underbody cover.





6. Remove the engine mount.

7. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Using the special tool, remove and discard the crankshaft front oil seal.





8. Remove the 3 bolts and the coolant pump pulley.
9. Disconnect the power steering pressure (PSP) switch electrical connector.

10. NOTE: The bolt that is positioned under the power steering pressure tube fitting will remain with the pump.

Remove the 3 power steering pump bolts and position the power steering pump aside.
11. Disconnect the crankshaft position (CKP) sensor electrical connector.

12. NOTE: Whenever the CKP sensor is removed, a new one must be installed, using the alignment tool supplied with the new part.

Remove the 2 bolts and the CKP sensor.
^ Discard the CKP sensor.

13. Remove the 22 bolts and the engine front cover.





Installation

1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs 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.

2. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.

Apply a 2.5 mm (0.09 inch) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 inch) bead of silicone gasket and sealant to the front cover.





3. Install the engine 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 13-mm bolts to 48 Nm (35 ft. lbs.).





4. Position the power steering pump and install the 3 bolts.

5. NOTE: The coolant pump pulley bolts should be tightened after the accessory drive belt is installed.

Install the coolant pump pulley and bolts.
^ Tighten to 20 Nm (15 ft. lbs.).

6. NOTE: Remove the through-bolt from the special tool.

NOTE: Lubricate the oil seal with clean engine oil.

Using the special tool, install the crankshaft front oil seal.





7. Install the engine mount.
8. Install the crankshaft pulley.

9. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Install a standard 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover.





10. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.

Install a new CKP sensor.
^ Do not tighten the bolts at this time.





11. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.

Adjust the new CKP sensor with the alignment tool.
^ Tighten the bolts to 7 Nm (62 inch lbs.).





12. Connect the CKP sensor electrical connector.
13. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





14. If equipped, install the underbody cover and the 7 screws.





15. Install the accessory drive belt and idler pulley.
16. Tighten the 3 coolant pump pulley bolts to 20 Nm (15 ft. lbs.).