Timing Cover: Service and Repair
Engine Front Cover, Timing Gears, Chain and TensionersSpecial Tools And Equipment:
Special Tool(s)
Material:
Material
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.
1. With the vehicle in neutral, position it on a hoist.
2. Remove the generator.
3. Remove the coolant pump.
4. Remove the camshaft synchronizer.
5. Remove the parts in the order indicated in the illustrations and tables.
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
To remove individual parts, only carry out the listed steps:
6. To install, reverse the removal procedure.
7. Drain the engine oil and refill with clean engine oil.
Item 8: Crankshaft Pulley Removal Note
1. Disconnect the RH front anti-lock brake wheel sensor electrical connector.
2. Position a safety stand under the RH side of the subframe.
3. Lower the RH side of the subframe 50.8 mm (2 inch).
^ Remove the bolts.
^ Lower the subframe.
4. Using the special tool, remove the crankshaft pulley.
5. Raise the subframe into position, then install the bolts.
Item 9: Crankshaft Front Seal Removal Note
1. Using the special tool, remove the front crankshaft front seal.
Item 11: Engine Front Cover Stud Bolt Removal Note
1. Disconnect the catalyst monitor sensor electrical connector.
2. Remove the catalyst monitor sensor electrical connector mounting bracket.
Item 13: Engine Front Cover Cap Screw Removal Note
1. CAUTION: The cap screw is hidden by the oil filter housing. Failure to remove this retainer will result in damage to the engine front cover.
Remove the engine front cover cap screw.
Items 14-15: Engine Front Cover and Stud Removal Note
1. NOTE: Mark the studs so they can be reinstalled in their original location.
Loosen the engine front cover studs and remove them with the engine front cover.
Items 17-23: Timing Components Removal Note
1. Remove the synchronizer drive gear.
1. Remove the bolt.
2. Remove the synchronizer drive gear.
2. Rotate the crankshaft until the timing marks and keyways align.
3. Compress and install a retaining pin to hold the timing chain tensioner.
4. Remove the camshaft gear, crankshaft gear and the timing chain as an assembly.
5. Remove the bolts and the timing chain tensioner.
Items 23-17: Timing Components Installation Note
1. Install the timing chain tensioner and bolts.
2. If necessary, retract the tensioner pad retracting mechanism and insert a retaining pin.
3. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at the 12 o'clock position.
4. Turn the camshaft gear so that the timing mark is on the bottom of the balance shaft.
5. Install the timing chain, crankshaft gear and camshaft gear as an assembly.
6. Make sure that the timing marks and the keyways are aligned.
7. Remove the retaining pin.
8. Install the synchronizer drive gear.
Items 16-10: Engine Front Cover Installation Note
1. CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover, it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage.
CAUTION: Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in engine damage.
Clean and inspect the engine block and front cover as follows:
^ Pack the exposed portion of the oil pan with clean shop towels.
^ Plug the oil and coolant passages.
^ Clean the gasket surfaces.
^ Clean all surfaces requiring gasket sealant with metal surface cleaner.
^ Using compressed air, remove any remaining foreign material from the engine block and front cover.
^ Remove the shop towels from the oil pan.
^ Remove the plugs or seals from the oil and coolant passages.
2. Apply a small amount of silicone gasket and sealant as shown.
3. Install the engine front cover gasket and apply a small amount of silicone gasket and sealant as shown.
Timing Cover Torque Sequence:
4. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
NOTE: Use pipe sealant with tenon on studs No. 4, 6 and bolt No. 12.
Install the engine front cover with the engine front cover studs in their original locations.
^ Tighten the engine front cover studs to 7 Nm (62 inch lbs.).
^ Using a new gasket, install the coolant pump.
^ Tighten the fasteners in the sequence shown.
^ Tighten bolt No. 12 to 10 Nm (89 inch lbs.).
^ Tighten all other fasteners to 28 Nm (21 ft. lbs.).
5. Install the two oil pan bolts and tighten to 10 Nm (89 inch lbs.).
6. Install the catalyst monitor sensor electrical connector bracket.
7. Connect the catalyst monitor sensor electrical connector.
Item 9: Crankshaft Front Seal Installation Note
1. Clean and inspect the mating surface.
2. NOTE: Lubricate the crankshaft front seal lips with clean engine oil prior to installation.
Assemble the special tools, then place the crankshaft front seal onto the special tools.
3. Using the special tools, install the crankshaft front seal.
Item 8: Crankshaft Pulley Installation Note
1. Lower the RH side of the subframe 50.8 mm (2 inch)
^ Remove the bolts.
^ Lower the subframe.
2. NOTE: Apply a bead of sealant to the keyway in the crankshaft pulley.
Using the special tool, install the crankshaft pulley.
3. Raise the subframe into position, then install the bolts.
4. Connect the RH front anti-lock brake wheel sensor electrical connector.
Item 5: Oil Filter Installation Note
1. Tighten oil filter one half turn after gasket makes contact with oil filter housing.