Timing Cover: Service and Repair
Engine Front Cover
Removal
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Drain the cooling system. For additional information, refer to Cooling System.
3. Remove the crankshaft front seal.
4. Remove the nut and detach the wiring harness bracket from the front cover.
5. Remove the 5 oil pan-to-front cover bolts.
6. Disconnect the lower radiator hose.
7. Remove the bolt and the drive belt tensioner.
8. Disconnect the heater hose from the coolant pump.
9. Disconnect the crankshaft position (CKP) sensor electrical connector.
10. Disconnect the generator electrical connectors and the wiring harness retainer.
11. Remove the 3 generator bracket bolts and the generator bracket.
12. Remove the coil bracket-to-LH accessory drive bracket bolt.
13. Remove the 4 bolts and the LH accessory drive bracket.
14. Remove and discard the CKP sensor wiring harness retainers.
15. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
16. Disconnect the upper radiator hose from the thermostat housing.
17. Disconnect the heater hose from the thermostat housing.
18. NOTE: The bypass hose will be removed with the thermostat housing.
Release the bypass hose clamp from the coolant pump end.
19. Remove the 3 bolts and the thermostat housing.
20. NOTE: Note the positions of the stud bolts for installation reference.
Remove the 10 bolts, the engine front cover and the gasket. Discard the gasket.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old front cover gasket and the silicone sealer
Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a plastic scraping tool. Follow the directions on the packaging.
2. Position the front cover gasket.
CAUTION: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces.
4. Apply silicone gasket and sealant to the front cover in 2 places.
5. NOTE: Make sure the stud bolts are installed in their original positions.
Position the engine front cover and install the 10 bolts.
^ Tighten to 19 Nm (14 lb-ft).
6. NOTE: Make sure the coolant bypass hose is attached to the coolant pump.
Position the thermostat housing and install the 3 bolts.
^ Tighten to 11 Nm (8 lb-ft).
7. Position the bypass hose clamp.
8. Connect the upper radiator hose to the thermostat housing.
9. Connect the heater hose to the thermostat housing.
10. Connect the ECT sensor electrical connector.
11. Install new wiring harness retainers and position the CKP sensor wiring.
12. Connect the CKP sensor electrical connector.
13. Position the LH accessory drive bracket and install the 4 bolts.
^ Tighten to 42 Nm (31 lb-ft).
14. Install the ignition coil bracket-to-LH accessory drive bracket bolt.
^ Tighten to 10 Nm (89 lb-in).
15. Position the generator bracket and install the 3 bolts.
^ Tighten to 42 Nm (31 lb-ft).
16. Connect the generator electrical connectors and the wiring harness retainer.
^ Tighten to 9 Nm (80 lb-in).
17. Connect the heater hose to the coolant pump.
18. Position the accessory drive belt tensioner and install the bolt.
^ Tighten to 47 Nm (35 lb-ft).
19. Connect the lower radiator hose.
20. Install the 5 cylinder block cradle-to-front cover bolts.
^ Tighten to 14 Nm (10 lb-ft).
21. Position the wiring harness bracket and install the nut.
^ Tighten to 20 Nm (15 lb-ft).
22. Install the crankshaft front seal.
23. Connect the battery ground cable. For additional information, refer to Battery.
24. Fill the engine cooling system.