Timing Cover: Service and Repair

Engine Front Cover

Special Tools:

Removal

CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley 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 tools, otherwise severe engine damage may 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. Disconnect the battery ground cable.

2. Remove the crankshaft pulley.





3. Release the wiring harness.
1. Remove the nuts retaining the wiring harness.
2. Release the wiring harness from the front cover studs and position aside.





4. NOTE: If the Crankshaft Position (CKP) sensor is damaged during engine front cover removal, a new CKP sensor must be installed.

Disconnect the CKP sensor electrical connector.





5. Remove the accessory belt tensioner.
1. Remove the bolts.
2. Remove the tensioner.





6. Disconnect the Power Steering Pressure (PSP) switch electrical connector.





7. Remove the nut and detach the PSP tube bracket.





8. Using the special tool, remove the power steering pump pulley.





9. Disconnect the PSP tube.
- Remove and discard the O-ring seal.





10. Remove the four bolts and position the power steering pump aside.





11. Remove the coolant pump pulley.

12. Remove the RH motor mount.





13. Remove the accessory drive belt idler pulley.





14. Remove the retainers 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 four minutes of applying the silicone gasket and sealant.

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





3. Install the 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 four retaining bolts.





5. Using the special tool, install a new O-ring on the PSP tube fitting.





6. Connect the power steering PSP tube fitting.





7. NOTE: Make sure the pulley is flush with the end of the power steering pump shaft.

Using the special tool, install the power steering pump pulley.





8. Attach the PSP tube bracket and install the nut.





9. Connect the PSP switch electrical connector.





10. Install the coolant pump pulley and the bolts.





11. Install the accessory drive belt idler pulley and the bolt.





12. Install the accessory belt tensioner.
1 Position the tensioner.
2 Install the tensioner bolts.


13. Install the RH motor mount.





14. NOTE: If the Crankshaft Position (CKP) sensor is damaged during engine front cover installation, a new CKP sensor must be installed.

Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.

15. CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using 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.

Install the crankshaft pulley.
16. Connect the battery ground cable.
17. Fill and purge the power steering fluid.