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 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. Remove the accessory drive belt and idler pulleys.
3. Remove the crankshaft pulley.
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: 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.

12. Remove the 3 bolts and the coolant pump pulley.
13. Disconnect the crankshaft position (CKP) sensor electrical connector.
^ Detach the 2 wiring harness retainers from the engine front cover.

14. 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.
15. 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 (0.10 inch) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.10 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. Install the coolant pump pulley and the 3 bolts.
^ Tighten to 25 Nm (18 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. Install the engine mount.
7. Install the crankshaft pulley.

8. 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.

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

10. Adjust the new CKP sensor with the alignment jig.
^ Tighten the 2 bolts to 7 Nm (62 inch lbs.).

11. Connect the CKP sensor electrical connector.
^ Attach the 2 wiring harness retainers to the engine front cover.
12. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.

13. Position the power steering pump and install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
14. Using the special tool, install a new Teflon O-ring seal to the PSP tube.

15. Install the PSP tube onto the power steering pump.
^ Tighten to 65 Nm (48 ft. lbs.).
16. Install the PSP tube bracket nut.
^ Tighten to 11 Nm (8 ft. lbs.).
17. Using the special tool, install the power steering pump pulley.

18. Connect the PSP switch electrical connector.
19. If equipped, attach the 2 wiring harness retainers to the power steering reservoir.
20. Install the accessory drive belt and idler pulleys.
21. Fill the power steering system.