Timing Cover: Service and Repair

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ENGINE FRONT COVER REMOVAL / INSTALLATION - 4.0L

Removal

1. With the vehicle in NEUTRAL, position it on a hoist. See Lifting.

2. Disconnect the battery. See Procedures.

3. Remove the crankshaft front seal. See - Service and Repair.

4. Drain the cooling system. See - Removal and Replacement.

1. Remove the nut and detach the A/C hose bracket from the front cover.

2. Remove the 5 cylinder block cradle-to-front cover bolts.

1. Remove the bolt and the wiring harness bracket.

2. Remove the A/C compressor and power steering bracket bolts and position the bracket aside.

3. Remove the nut and disconnect the generator wiring terminal.

4. Disconnect the 2 generator electrical connectors and the wiring harness retainer.

5. Remove the bolt and the accessory drive belt tensioner.

6. Remove the bolts and the generator mounting bracket.

7. Disconnect the crankshaft position (CKP) sensor electrical connector.

8. Detach the wiring harness retainer.

9. Detach the wiring harness anchors and position the wiring harness aside.

- Discard the anchors.

1. Remove the bolt and position the wiring harness aside.

1. Position the bypass hose clamp off of the coolant pump outlet.

2. Disconnect the heater hose from the coolant pump.

3. Disconnect the lower radiator hose from the coolant pump.

4.
NOTE:Note the positions of the stud bolts for installation reference.Remove the 5 bolts, the 5 stud bolts, the engine front cover and the gasket.
a. Discard the gasket.

Installation Note

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.

1.

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.Apply silicone gasket and sealant to the front cover in 2 places.

2.
NOTE:Make sure the coolant bypass hose is attached to the coolant pump.
NOTE:Make sure the stud bolts are installed in their original positions.
Position the engine front cover and install the 5 bolts and 5 stud bolts.Tightening Torque19 Nm {1.9 kgf-m, 14 ft-lbf}

3.
NOTE:The 5 bolts may or may not have washers. All the bolts should be of the same type.Install the 5 cylinder block cradle-to-front cover bolts.Tightening Torque With washers: 10 Nm {1.0 kgf-m, 89 in-lbf}Without washers: 14 Nm {1.4 kgf-m, 10 ft-lbf}

4. Position the bypass hose clamp.

5. Connect the lower radiator hose to the coolant pump.

6. Connect the heater hose to the coolant pump.

1. Position the wiring harness and install the bolt.Tightening Torque10 Nm {1.0 kgf-m, 89 in-lbf}

2. Install new wiring harness anchors and position the CKP sensor wiring.

3. Attach the wiring harness retainer.

4. Connect the CKP sensor electrical connector.

5. Position the A/C compressor and power steering bracket and install the 4 bolts.Tightening Torque42 Nm {4.3 kgf-m, 31 ft-lbf}

6. Position the generator bracket and install the 3 bolts.Tightening Torque42 Nm {4.3 kgf-m, 31 ft-lbf}

7. Position the accessory drive belt tensioner and install the bolt.Tightening Torque47 Nm {4.8 kgf-m, 35 ft-lbf}

8. Connect the generator electrical connectors and the wiring harness retainer.

9. Attach the generator terminal and install the nut.Tightening Torque8 Nm {0.8 kgf-m, 71 in-lbf}

1. Position the A/C tube bracket and install the nut.Tightening Torque20 Nm {2.0 kgf-m, 15 ft-lbf}

2. Drain the engine oil. Install the drain plug when finished.Tightening Torque26 Nm {2.5 kgf-m, 19 ft-lbf}

3. Install the crankshaft front seal. See - Service and Repair.

4. Fill the engine with clean engine oil.

5. Connect the battery.

6. Fill the engine cooling system. See - Removal and Replacement.