Timing Cover: Service and Repair

Engine Front Cover Replacement

Tools Required
* J 35354-A Seal Installer
* J 38185 Hose Clamp Pliers
* J 45059 Angle Meter

Removal Procedure




1. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
2. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair).
3. Lower the vehicle.
4. Loosen the water pump pulley bolts.
5. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (Service and Repair).
6. Remove the water pump pulley.




7. Remove the power steering pump bolts and reposition the pump.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
9. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (Service and Repair).





Important: Be careful not to damage the crankshaft.


10. Pry out the crankshaft front oil seal with a flat-bladed tool. Use care to avoid damaging the crankshaft front oil seal bore or the crankshaft front oil seal contact surfaces.




11. Disconnect the ignition control module wiring harness electrical connector (3) from the crankshaft position (CKP) sensor.




12. Disconnect the ignition control module wiring harness electrical connector (3) from the camshaft position (CMP) sensor.




13. Disconnect the engine harness electrical connector (2) from the oil pressure sensor.




14. Remove the CKP sensor shield.




15. Using the J 38185 reposition the radiator outlet hose clamp.
16. Remove the radiator outlet hose from the engine front cover.
17. Lower the vehicle.
18. Install the engine support fixture. Refer to Engine Support Fixture (Engine Support Fixture).
19. Raise the vehicle.




20. Remove the oil filter.
21. Remove the engine mount bracket. Refer to Engine Front Mount Bracket Replacement (Service and Repair).




22. Disconnect the engine harness electrical connector (2) from the oil level sensor.





Important: The oil pan can be dropped slightly for engine front cover clearance if all pan bolts are loosened and the oil level sensor is removed.


23. Remove the oil level sensor.
24. Remove the oil pan-to-engine front cover bolts.
25. Remove the oil pan. Refer to Oil Pan Replacement (Service and Repair).




26. Remove the CKP sensor studs and sensor.




27. Remove the engine front cover bolts/stud.
28. Remove the engine front cover.




29. Remove the engine front cover gasket.




30. If replacing the engine front cover, perform the following steps, otherwise proceed to step 14 in the installation procedure.
31. Remove the oil filter adapter bolts.
32. Remove the oil filter adapter and gasket.
33. Remove the oil pressure relief valve and spring.




34. Remove the water pump bolts.
35. Remove the water pump and gasket.




36. Remove the oil pump cover screws.
37. Remove the oil pump cover.
38. Remove the oil pump gear set.




39. Remove the CMP sensor bolt.
40. Remove the CMP sensor.
41. Inspect the timing chain for overall in and out movement. Maximum movement is 25.4 mm (1 in). Refer to Camshaft Timing Chain and Sprocket Cleaning and Inspection ().
42. Inspect the sprockets for wear.
43. Clean and inspect the water pump. Refer to Water Pump Cleaning and Inspection (Overhaul).
44. Clean and inspect the oil pump. Refer to Oil Pump Cleaning and Inspection (Overhaul).
45. Clean the engine front cover mating surfaces.

Installation Procedure




1. If replacing the engine front cover Refer to the following steps, otherwise proceed to step 14.
2. Install the CMP sensor.

Notice: Refer to Fastener Notice (Fastener Notice).

3. Install the CMP sensor bolt.

Tighten the bolt to 10 N.m (89 lb in).




4. Lubricate the oil pump gear set with petroleum jelly.
5. Install the oil pump gear set.
6. Pack the oil pump gears with petroleum jelly.
7. Install the oil pump cover.
8. Install the oil pump cover screws.

Tighten the screws to 11 N.m (98 lb in).




9. Position the water pump gasket and water pump.
10. Install the water pump bolts.

Tighten the bolts to 15 N.m (11 lb ft) plus an additional 80 degrees usingJ 45059.




11. Install the pressure relief valve spring and valve.
12. Position the oil filter adapter gasket and adapter.
13. Install the oil filter adapter bolts.

Tighten the bolts to 50 N.m (30 lb ft) plus an additional 3 degrees usingJ 45059.




14. Install a NEW engine front cover gasket.
15. Apply sealer to the engine front cover bolts/stud threads. Refer to Adhesives, Fluids, Lubricants, and Sealers (Specifications) for the correct part number.




16. Install the engine front cover.
17. Install the engine front cover bolts/stud.

Tighten the bolts to 20 N.m (15 lb ft) plus an additional 40 degrees usingJ 45059.




18. Install the CKP sensor and studs.

Tighten the studs to 20 N.m (15 lb ft) plus an additional 40 degrees usingJ 45059.




19. Install the oil pan. Refer to Oil Pan Replacement (Service and Repair)
20. Install the oil level sensor.

Tighten the sensor to 20 N.m (15 lb ft).




21. Connect the engine harness electrical connector (2) to the oil level sensor.




22. Install the oil filter.

Tighten the filter to 30 N.m (22 lb ft).

23. Install the engine mount bracket. Refer to Engine Front Mount Bracket Replacement (Service and Repair).




24. Lower the vehicle.
25. Remove the engine support fixture.
26. Raise the vehicle.
27. Install the radiator outlet hose to the engine front cover.
28. Using the J 38185 position the radiator outlet hose clamp.




29. Install the NEW engine front cover seal usingJ 35354-A.
30. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover.
31. Remove the J 35354-A.




32. Install the CKP sensor shield.




33. Connect the engine harness electrical connector (2) to the oil pressure sensor.




34. Connect the ignition control module wiring harness electrical connector (3) to the CKP sensor.




35. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (Service and Repair).
36. Lower the vehicle.
37. Position and install the power steering pump and bolts.

Tighten the bolts to 34 N.m (25 lb ft).




38. Install the water pump pulley.
39. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (Service and Repair).
40. Tighten the water pump pulley bolts.

Tighten the bolts to 13 N.m (115 lb in).

41. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair).
42. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
43. Inspect for leaks.
44. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Programming and Relearning).