Timing Cover: Service and Repair

REMOVAL
1. Disconnect battery.

Figure 28 Air Cleaner Assembly - Roadster:

2. Remove air Cleaner assembly and hoses to throttle bodies.
3. Drain cooling system.
4. Remove coolant hoses from engine and radiator.
5. Remove drive belt.

Figure 29 Generator - Removal:

6. Remove generator wiring. Remove generator.
7. If equipped with A/C remove compressor mounting bolts.

Figure 30 Oil Filter Adapter:

8. If replacing timing chain cover, remove oil filter adapter and discard gasket. If only removing timing chain cover, remove oil cooler lines at oil filter adapter.

Figure 31 Crankshaft Pulley - Removal:

Figure 32 Vibration Damper - Removal:

9. Remove crankshaft pulley and vibration damper.
10. Disconnect cam sensor electrical connector at chain case cover.

NOTE: When removing the timing chain cover, it is NOT necessary to remove the camshaft sensor.

Figure 33 Timing Chain Case Cover Fasteners:

11. Remove chain case cover fasteners and remove chain case cover. Remove crankshaft oil seal and discard.

INSTALLATION
1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed to insure correct oil pump engagement.

Figure 34 Timing Chain Case Cover Gasket:

2. Use a new cover gasket.
3. Rotate crankshaft so that the oil pump drive flats are vertical.
4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats.
5. Install cover onto crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.
6. Install chain case cover screws and torque to 40 Nm (30 ft. lbs.).

Figure 35 Crankshaft Oil Seal - Installation:

7. Install crankshaft oil seal.

Figure 36 Vibration Damper - Installation:

8. Install crankshaft damper.
9. Install crankshaft pulley.
10. If oil filter adapter was removed, install oil filter adapter using a new gasket to timing chain cover and torque screws to 11 Nm (95 inch lbs.). If oil cooler lines were removed, install lines to oil filter adapter fittings.
11. If equipped with A/C, install compressor mounting bolts to cover and block. Torque screws to 23 Nm (200 inch lbs.).
12. Install generator and torque screws to 40 Nm (30 ft. lbs.).
13. Connect cam sensor electrical connector and generator wiring.
14. Install drive belt.
15. Fill cooling system.