9-3 1999

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation





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Fig. Exploded view of the timing chain front cover assembly-2.0L engine



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Fig. Be sure to align the crankshaft timing mark, as shown-2.0L engine



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Fig. Secure the engine in position using a flywheel locking tool-2.0L and 2.3L engines



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Fig. Unthread the timing chain tensioner to remove it from the front cover-2.0L and 2.3L engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Bracket for the steering servo pump, complete with the pump and alternator
     
    Belt tensioner and the water pump pipe
     
    Crankshaft pulley
     
    Oil pipes
     
    Water pump pulley
     
    Timing chain cover
     
    Oil seal
     

  8.  
  9. The cam chain and crankshaft timing sprocket should now both be visible. From above, release the timing chain tensioner by pressing the pivoting guide firmly against it. Remove the chain tensioner.
  10.  
  11. Using a wrench to hold the cast hex bolt on the camshafts, remove the center bolts securing the camshaft sprockets. Throughout this procedure, keep the camshafts in their basic correct setting. If they are rotated out of position at any stage, especially without their sprockets and chain, the valves can be damaged.
  12.  
  13. Disconnect the timing chain from the sprockets and remove the chain, clearing it from the crankshaft sprockets.
  14.  

To install:

  1. Using a suitable seal installer, tap the new seal into the front cover until it is flush with the casting.
  2.  
  3. To install the timing chain, place the chain around the crankshaft sprocket. Run the chain up through the opening in the cylinder head. Install the chain and sprocket on the exhaust cam first. Be sure the chain is taut between the crankshaft and camshaft sprockets. Install and snug the bolt but do not tighten.
  4.  
  5. Install the chain and sprocket to the intake cam. Keep the chain taut between the cam sprockets while it is being installed. Install and snug the bolt but do not tighten. Be sure the chain is seated in the guide tensioner grooves.
  6.  
  7. Tension the chain tensioner by fully depressing the piston, then rotating it to the locked position.
  8.  
  9. Install the chain tensioner with the piston under tension. Be sure the copper gasket is in good condition and that the sealing surface is clean and free from burrs. Torque the tensioner to 47 ft. lbs. (63 Nm).
  10.  
  11. Trigger the chain tensioner by pressing the pivoting chain guide against it, thereafter, press the pivoting guide against the chain to give the chain its basic tension. Check that the chain tensioner maintains tension on the chain when the pressure on the chain guide is released and that the basic setting stop for the tensioner holds the chain guide tight against the chain. A limited amount of play will be present until the hydraulic pressure takes over once the engine is running.
  12.  
  13. Check the setting by rotating the crankshaft 2 complete turns in its normal direction of rotation around to the timing mark. The basic setting of the cams should remain unaltered.
  14.  
  15. Lock the exhaust cam by using a wrench on the cast hex bolt and torque the sprocket bolt to 48 ft. lbs. (65 Nm). Repeat this on the intake cam.
  16.  
  17. Complete the procedure on the intake cam sprocket. When loosening or tightening the sprocket center bolts, hold the cam still using a wrench installed over the flats on the camshaft.
  18.  
  19. Install or connect the following:

    Timing cover and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Oil pump
     
    Oil supply pipes
     
    Water pump pulley
     
    Crankshaft pulley and torque the nut to 140 ft. lbs. (190 Nm)
     
    Belt tensioner
     
    Water pump pipe
     
    Power steering pump
     
    Alternator
     
    Drive belt
     
    Negative battery cable
     

  20.  
  21. Fill the cooling system to the proper level.
  22.  
  23. Fill the engine with clean oil.
  24.  
  25. Start the engine, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Installing the front crankshaft seal-2.0L and 2.3L engines

  26.  

 
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