Engine Timing Cover(s) - Installation

INSTALLATION










1. Be sure the mating surfaces of the chain case cover and cylinder block are clean and free from burrs. The crankshaft oil seal must be removed to insure correct oil pump engagement.

NOTE: DO NOT USE SEALER ON COVER GASKET

2. Position a new gasket (1) on the timing cover (2). Adhere the new gasket to the chain case cover, making sure that the lower edge of the gasket is flush to 0.5 mm (0.020 in.) passed the lower edge of the cover.
3. Rotate the crankshaft so that the oil pump drive flats are in the vertical position.
4. Position the oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats.

CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.

5. Install the timing cover and timing chain cover bolts. Tighten M8 bolts to 27 Nm (20 ft. lbs.) and M10 bolts to 54 Nm (40 ft. lbs.).










6. Install the crankshaft front oil seal (2) Front Crankshaft Oil Seal - Installation.










7. Install the water pump and pulley Water Pump - Installation.










8. Install the accessory drive belt idler pulley (1). Tighten the bolt (2) to 28 Nm (250 in. lbs.).










9. Install the accessory drive belt tensioner (2). Tighten the bolt (1) to 28 Nm (250 in. lbs.).





10. Position the power steering pump (2) on the engine.
11. Install three power steering pump mounting bolts (1) through openings in the pulley. Tighten pump mounting bolts to 23 Nm (17 ft. lbs.).





12. Position the generator (1) on the engine and install two mounting bolts (2) and (3). Tighten both bolts to 54 Nm (40 ft. lbs.).





13. Install the bracket (3) to the generator and stud. Tighten the bolt (1) and nut (2) to 28 Nm (21 ft. lbs.).





14. Install the front cover support bracket (5) with two bolts (3) and nut (4). Tighten the nut (4) to 22 Nm (200 in. lbs.). Tighten the bolts (3) to 25 Nm (18 ft. lbs.).
15. Position the power steering line support bracket (2) and install the mounting bolt (1). Tighten the bolt to 10 Nm (89 in. lbs.).










16. Install the right side engine mount Engine Mount Insulator - Installation.





17. Install the camshaft position sensor to the timing chain cover Camshaft Position Sensor - Installation.










18. Connect the heater return hose to the timing chain cover housing or water pump inlet tube (if equipped with an engine oil cooler).
19. Connect the lower radiator hose (2).










20. Install the crankshaft vibration damper (2) Vibration Damper - Installation.





21. Position the A/C compressor (7) onto the engine and tighten the nuts (5 and 6) and bolt (2) in the following sequence:
- Install the bolt (2) and hand tighten.
- Install the nuts (5 and 6) and hand tighten.
- Tighten front 8mm nuts (6) to 23 Nm (17 ft. lbs.).
- Tighten rear upper 10 mm bolt (2) to 40 Nm (30 ft. lbs.).
- Tighten rear lower 10 mm nut (5) onto the stud with spacer (4) to 40 Nm (30 ft. lbs.).










22. Install accessory drive belt (1) Serpentine Accessory Drive Belt - Installation.










23. Install the oil pump pick-up tube (2) with new O-ring (3). Tighten the attaching bolt (1) to 28 Nm (250 in. lbs.).
24. Install the oil pan Engine Oil Pan - Installation.










25. Install the right front inner splash shield (3).
26. Install the right front tire and wheel assembly Tires and Wheels - Installation
27. Fill the crankcase with engine oil to proper level Service and Repair.
28. Fill cooling system Service and Repair.
29. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).