Timing Cover: Service and Repair

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ENGINE FRONT COVER REMOVAL/INSTALLATION - 2.5L










Removal

CAUTION:Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

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. See Lifting.

2. Remove the accessory drive belt and idler pulleys. See - Service and Repair and - Service and Repair.

3. Remove the crankshaft pulley. See - Service and Repair.

4. Remove the engine mount. See - Removal and Replacement.






5. Using the special tool, remove the crankshaft front oil seal.

CAUTION:Use care not to damage the engine front cover or the crankshaft when removing the seal.
6. Remove the 3 bolts and the coolant pump pulley.

7. Remove the 2 bolts and the accessory drive belt idler pulley and bracket.

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

9. Remove and the 2 bolts and the CKP sensor.






10. Remove the bolts and the engine front cover.

Installation

1. Clean and inspect the mounting surfaces of the engine and the front cover.

CAUTION:Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.






2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.

NOTE:The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.






3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:

- Tighten the 8 mm bolts to 10 Nm {1.0 kgf-m, 89 in-lbf}.
- Tighten the 13 mm bolts to 48 Nm {4.9 kgf-m, 35 ft-lbf}.

4. Install the accessory drive belt idler pulley and bracket and the 3 bolts.

- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.

5. Install the water pump pulley and bolts.

- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.






6. Using the special tool, install the crankshaft front oil seal.

NOTE:Remove the through-bolt from the special tool.
NOTE:Lubricate the oil seal with clean engine oil.
7. Install the engine mount. See - Removal and Replacement.

8. Install the crankshaft pulley. See - Service and Repair.






9. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.

CAUTION:Only hand-tighten the bolt or damage to the front cover can occur.






10. Install a new CKP sensor and the 2 bolts.

- Do not tighten the bolts at this time.






11. Adjust the CKP sensor with the alignment tool.

- Tighten the 2 CKP bolts to 7 Nm {0.7 kgf-m, 62 in-lbf}.

12. Connect the CKP sensor electrical connector.






13. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.

14. Install the accessory drive belt and idler pulleys. See - Service and Repair and - Service and Repair.