Timing Cover: Service and Repair

Engine Front Cover

Special Tool(s):

Material:

Removal

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.

CAUTION: 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. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

NOTE: Early build vehicles are equipped with a remote power steering reservoir located at the rear of the engine compartment. Late build vehicles are equipped with a pump mounted reservoir.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the accessory drive belt and idler pulleys. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories.
3. Remove the valve cover.
4. Remove the engine mount.
5. If equipped, detach the 2 wiring harness retainers from the power steering reservoir.
6. Disconnect the power steering pressure (PSP) switch electrical connector.

7. Using the special tool, remove the power steering pump pulley.
8. Remove the PSP tube bracket nut.

9. NOTE: A new Teflon O-ring seal must be installed any time the PSP tube is disconnected from the power steering pump.

Disconnect the PSP tube from the power steering pump.
^ Remove and discard the Teflon O-ring seal.
10. Remove the 4 power steering pump mounting bolts and position the power steering pump aside.

11. CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
^ The hole in the crankshaft pulley should be in the 6 o'clock position.

12. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Install the special tool in the slots on the rear of both camshafts.

13. Remove the engine plug bolt.

14. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.

Install the special tool.

15. Install the special tools.

16. CAUTION: Failure to hold the crankshaft pulley in place while loosening the bolt can result in damage to the engine.

CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley it must be installed back onto the crankshaft.

Remove the crankshaft pulley.
^ Remove the crankshaft pulley bolt and washer.
^ Remove the crankshaft pulley.

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

Using the special tool, remove the crankshaft front oil seal.
18. Remove the 3 bolts and the coolant pump pulley.
19. Disconnect the crankshaft position (CKP) sensor electrical connector.
^ Detach the 2 wiring harness retainers from the engine front cover.

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

Remove and discard the CKP sensor.

21. Remove the bolts and the engine front cover.

Installation

1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks 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 these specifications:
^ Tighten the 8-mm bolts to 10 Nm (89 inch lbs.).
^ Tighten the 13-mm bolts to 48 Nm (35 ft. lbs.).
4. Install the coolant pump pulley and the 3 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).

5. 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.

6. NOTE: Do not reuse the crankshaft pulley bolt.

NOTE: Apply clean engine oil on the seal area before installing.

Install the crankshaft pulley and hand-tighten the bolt.

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

NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

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.
^ Rotate the pulley as necessary to align the bolt holes.

8. CAUTION: Failure to hold the crankshaft pulley in place while tightening the bolt can cause damage to the engine front cover.

Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
^ Stage 1: Tighten to 100 Nm (74 ft. lbs.).
^ Stage 2: Tighten an additional 90° (1/4 turn).

9. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.

10. Remove the special tool.

11. Remove the special tool.

12. NOTE: Only turn the engine in the normal direction of rotation.

Turn the engine 2 complete revolutions.

13. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft until the No. 1 piston is at TDC.

14. Install the special tool.

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

Using the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt, check the position of the crankshaft pulley.
^ If it is not possible to install the bolt, correct the engine timing.

16. Using the special tool, check the position of the camshafts.
^ If it is not possible to install the special tool, correct the engine timing.

17. Install the CKP sensor and the 2 bolts.
^ Do not tighten the bolts at this time.

18. Adjust the new CKP sensor with the alignment jig.
^ Tighten the 2 bolts to 7 Nm (62 inch lbs.).
19. Connect the CKP sensor electrical connector. Attach the 2 wiring harness retainers to the engine front cover.

20. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.

21. Install the engine plug bolt.
^ Tighten to 20 Nm (15 ft. lbs.).
22. Position the power steering pump and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

23. Using the special tool, install a new Teflon O-ring seal to the PSP tube.
24. Install the PSP tube onto the power steering pump.
^ Tighten to 65 Nm (48 ft. lbs.).
25. Install the PSP tube bracket nut.
^ Tighten to 11 Nm (8 ft. lbs.).

26. Using the special tool, install the power steering pump pulley.
27. Connect the PSP switch electrical connector.
28. If equipped, attach the 2 wiring harness retainers to the power steering reservoir.
29. Install the accessory drive belt and idler pulleys. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories.
30. Install the engine mount.
31. Install the valve cover.
32. Fill the power steering system.