N-Car Service Procedure

Tools Required:

J28467-A Engine Support Fixture (with long hooks)
J24420-B Cam Gear Removal Tool
J25033-B Cam Gear Installation Tool
J34995 Crankshaft Front Cover Oil Seal Installer
J8001 Universal Dial Indicator w/Magnetic Base

Remove or Disconnect

1. Negative battery cable.
2. Accessory drive belts.
3. Power steering pump mount bolts - lay pump aside.
4. Drain coolant (1985-86 only).
5. Timing pointer plate (1985-86 only).
6. Body ground strap.
7. Front end sheet metal diagonal brace (R.H.).
8. Install engine support fixture - J28467-A per Service Manual.
9. Upper front engine mount to body bolts (2).
10. Raise vehicle.
11. Right front wheel.
12. Right front brakeline-to-body bracket.
13. Right front wheelhouse engine splash shield.
14. Flywheel/flexplate cover.
15. Crankshaft pulley (have assistant hold flywheel).
16. Rear engine mount to bracket nuts and mount thru bolts.
17. Rear transaxle strut - automatic transaxle only (as applicable).
18. Lower front engine mount to body bolt (leave mount attached to engine).
19. Retaining bolts from right side front suspension support (6).
20. Retaining bolts from left side front suspension support (6).
21. Drain engine oil (remove oil filter).
22. Lower vehicle.
23. Transaxle mount thru bolt.
24. Lower engine/transaxle assembly with engine support fixture.
25. Raise vehicle.
26. Timing gear cover - do not distort.

Clean

- Timing gear cover and engine sealing surfaces.

27. Align crankshaft/camshaft timing marks on gears.
28. Drill and tap hole on the camshaft centerline (8 mm drill, 1/2 inch deep).

CAUTION: WEAR SAFETY GLASSES TO AVOID EYE DAMAGE.

USE CARE WHEN DRILLING AND TAPPING CAM GEAR TO AVOID DAMAGE TO THE CAMSHAFT.

IMPORTANT: COVER OIL PAN OPENING WITH RAGS TO PREVENT CHIPS FROM FALLING INTO PAN.

29. Tap the 8 mm hole with a 3/8-16-NC bottoming tap.

IMPORTANT: AVOID BUILD-UP OF CHIPS. BACK OUT THE TAP EVERY FEW TURNS AND REMOVE CHIPS.

30. Center punch and drill (2) 3 mm pilot holes in the metal hub of the cam gear (180 degrees apart).

IMPORTANT: USE CARE TO AVOID DRILL WANDER THAT COULD DAMAGE CAMSHAFT.

31. Enlarge pilot holes with 5.5 mm drill; 1/4 inch deep.
32. Tap 5.5 mm holes with 1/4-28-NF bottoming tap.
33. Drill a hole no larger than 1 mm (.040 in.) in the front oil gallery plug. This provides improved lubrication to the timing gears.

Clean

- Oil pan of debris.

34. Cam gear with J24420-B - do not move cam or crank.

Inspect

- Thrust plate for scuffing and/or grooving. If evident, install new thrust plate, spacer ring, and key. Thrust plate-to-block bolts torque 10 N-m (90 in.lbs.).


IMPORTANT: LUBRICATE FRONT THRUST PLATE SURFACE WITH CLEAN ENGINE OIL.

Install or Connect

1. Cam gear using J25033-B - align timing marks.
Measure

- Camshaft end play using dial indicator - J8001 or equivalent. Push cam gear onto camshaft until camshaft until camshaft end play is in the range of .0015 in. to .0050 in. (.04 mm to .13 mm).

2. J34995 into front cover - lubricate seal lip with clean engine oil.
3. Apply RTV sealant to timing gear cover sealing surfaces.
4. Timing gear cover to engine.
5. Lower vehicle.
6. Raise engine assembly with support fixture.
7. Thru bolt in rear transaxle mount.
8. Retaining bolts (2) in front engine mount.
9. Raise vehicle.
10. Retaining nuts (2) and thru bolts (2) in right front engine mount.
11. Retaining bolt (1) in left front engine mount.
12. Place axle stand under right front suspension support, raise into position and fasten with retaining bolts (6).
13. Place axle stand under left front suspension support, raise into position and fasten with retaining bolts.
14. Crankshaft pulley and bolt (w/assistant).
15. Flywheel/flexplate cover and bolts.
16. Engine splash shield.
17. Brakeline-to-body bracket.
18. Right front wheel.
19. Lower vehicle.
20. Transaxle bracket to transaxle mount long bolt.
21. Remove engine support fixture.
22. Timing pointer plate (1985-86 only).
23. Engine coolant (1985-86 only).
24. Engine oil (replace oil filter).
25. Power steering pump mount bolts to engine.
26. Accessory drive belts.
27. Front end sheet metal diagonal brace (R.H.).
28. Body ground strap.
29. Negative battery cable.
30. Check front end toe and adjust, if necessary.

Inspect

- For oil and coolant leaks with engine running at operating temperature.
- For proper completion of repairs.

Labor Operation Number: J0840

For 1987-88

Labor Time: 4.7 Hours

A/C - Add: .2 Hours

To Replace Crankshaft Gear - Add: .1 Hour

Automatic Transmission (1987 only) - Add: .1 Hour
Locking Wheel Covers and/or Nuts - Add: .1 Hour


For 1985-86

Labor Time: 5.1 Hours

A/C - Add: .2 Hours

To Replace Crankshaft Gear - Add: .1 Hour
Automatic Transmission - Add: .1 Hour
Locking Wheel Covers and/or Nuts - Add: .1 Hour