Timing Cover: Service and Repair

Engine Front Cover





















Removal

NOTICE: 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 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 service tools, otherwise severe engine damage can occur.

NOTICE: 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. For additional information, refer to Jacking and Lifting Service and Repair.

2. Loosen the 3 coolant pump pulley bolts.

3. Remove the accessory drive belt and the accessory drive idler pulley. For additional information, refer to Accessory Drive - 2.5L Accessory Drive Belt and Accessory Drive Belt Idler Pulley.

4. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley Crankshaft Pulley.

5. If equipped, remove the 7 screws and the underbody cover.





6. Remove the engine mount. For additional information, refer to Engine Mount Removal and Replacement.

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

Using the Oil Seal Remover, remove and discard the crankshaft front oil seal.





8. Remove the 3 bolts and the coolant pump pulley.

9. Remove the 2 bolts and the accessory drive belt idler pulley and bracket.

10. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

11. Remove the 2 bolts and the CKP sensor.

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





Installation

1. NOTICE: 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.

NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow these instructions can cause future oil leakage.

Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) 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 lb-in).

- Tighten the 13-mm bolts to 48 Nm (35 lb-ft).





4. Install the accessory drive belt idler pulley and bracket and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

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

Install the coolant pump pulley and bolts.

6. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer.

NOTE: Lubricate the oil seal with clean engine oil.

Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.





7. Install the engine mount. For additional information, refer to Engine Mount Removal and Replacement.

8. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley Crankshaft Pulley.

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

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





10. Install the CKP sensor and the 2 bolts.
- Do not tighten the bolts at this time.





11. Using the Crank Alignment Tool, adjust the CKP sensor.
- Tighten the bolts to 7 Nm (62 lb-in).





12. Connect the CKP sensor electrical connector.

13. Remove the 6 mm x 18 mm bolt.





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





15. Install the accessory drive belt and the accessory drive idler pulley. For additional information, refer to Accessory Drive - 2.5L Accessory Drive Belt and Accessory Drive Belt Idler Pulley.

16. Tighten the 3 coolant pump pulley bolts to 20 Nm (177 lb-in).