AMC Coupes/Sedans/Wagons 1975-1988 Repair Information

Timing Case Cover

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REMOVAL & INSTALLATION 4-150 Engine



Special tools are needed for this job.

See Figures 1, 2, 3 and 4

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Fig. Fig. 1: Timing cover assembly components4-150 engine



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Fig. Fig. 2: Typical oil pan gaskets4-150 engine



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Fig. Fig. 3: Install the timing cover centering tool on the crankshaft before tightening the cover bolts



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Fig. Fig. 4: Use tool J-9163-2 to install the timing cover oil seal4-150 engine

  1. Remove the drive belts and fan shroud.
  2.  
  3. Unscrew the vibration damper bolts and washer.
  4.  
  5. Using a puller, remove the vibration damper.
  6.  
  7. Remove the fan assembly. If the fan is equipped with a fan clutch do not lay it down! If you lay it down, the fluid will leak out of the clutch and irreversibly damage the fan.
  8.  
  9. Disconnect the battery ground.
  10.  
  11. Remove the air conditioning compressor/alternator bracket assembly and lay it out of the way. Do not disconnect the refrigerant lines!
  12.  
  13. Unbolt the cover from the block and oil pan. Remove the cover and front seal.
  14.  
  15. Cut off the oil pan side gasket end tabs and oil pan front seal tabs (indicated by the arrows in the illustration).
  16.  

To install:
  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Remove the seal from the cover.
  4.  
  5. Apply sealer to both sides of the new case cover gasket and position it on the block.
  6.  
  7. Cut the end tabs off the new oil pan side gaskets corresponding to those cut off the original gasket and attach the tabs to the oil pan with gasket cement.
  8.  
  9. Coat the front cover seal end tab recesses generously with RTV sealant and position the side seal in the cover.
  10.  
  11. Apply engine oil to the seal-to-pan contact surface.
  12.  
  13. Position the cover on the block.
  14.  
  15. Insert alignment tool J-22248 or its equivalent into the crankshaft opening in the cover.
  16.  
  17. Install the cover bolts. Tighten the cover-to-blockbolts to 5 ft. lbs.; the cover-to-pan bolts to 11 ft. lbs.
  18.  
  19. Remove the alignment tool and position the new front seal on the tool with the seal lip facing outward. Apply a light film of sealer to the outside diameter of the seal. Lightly coat the crankshaft with clean engine oil.
  20.  
  21. Position the tool and seal over the end of the crankshaft and insert the Draw Screw J-9163-2 or its equivalent into the installation tool.
  22.  
  23. Tighten the nut until the tool just contacts the cover.
  24.  
  25. Remove the tools and apply a light film of engine oil on the vibration damper hub contact surface of the seal.
  26.  
  27. With the key inserted in the keyway in the crankshaft, install the vibration damper, washer and bolt. Lubricate the bolt and tighten it to 108 ft.lb.
  28.  
  29. Install all other parts in reverse order of removal.
  30.  

4-151 Engine See Figures 5, 6, 7 and 8

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Fig. Fig. 5: Apply sealer to the locations indicated before installing the front cover4-151 engine



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Fig. Fig. 6: Use a razor to cut the oil pan seal as indicated4-151 engine



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Fig. Fig. 7: Apply a 1/8 in. bead of sealer to the areas indicated on the block4-151 engine



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Fig. Fig. 8: Place an alignment tool in the cover seal and tighten the bolts4-151 engine

  1. Disconnect the battery ground.
  2.  
  3. Remove the crankshaft pulley hub.
  4.  
  5. Remove the alternator bracket.
  6.  
  7. Remove the fan and radiator shroud.
  8.  
  9. Remove the oil pan-to-timing case cover bolts.
  10.  
  11. Pull the cover forward just enough to allow cutting the oil pan front seal flush with the block on both sides of the cover. Use a sharp knife or razor.
  12.  
  13. Remove the front cover.
  14.  

To install:
  1. Clean the gasket surface on the block and cover.
  2.  
  3. Cut the tabs from the new oil pan front seal.
  4.  
  5. Install the seal on the cover, pressing the tips into the holes provided in the cover.
  6.  
  7. Coat a new gasket with sealer and place on the cover.
  8.  
  9. Apply a 1 / 8 in. (3.175mm) bead of RTV sealant to the joint formed at the oil pan and block.
  10.  
  11. Install an aligning tool such as tool J-23042 or its equivalent in the timing case cover seal.
  12.  

It is important that an aligning tool is used to avoid seal damage and to ensure a tight, even seal fit.

  1. Position the cover on the block and partially retighten the two oil pan-to-cover bolts.
  2.  
  3. Install the remaining bolts, and tighten all bolts to 45 inch lbs.
  4.  
  5. Install all other parts in reverse order of removal. Tighten the fan assembly bolts to 18 ft. lbs.
  6.  

6-232 and 258 Engines

COVER REMOVED

See Figures 9, 10 and 11

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Fig. Fig. 9: Exploded view of the timing case cover and its related components6-cylinder engine



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Fig. Fig. 10: Use tool J-9163 with the alignment tool to install the seal6-cylinder 258 engine



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Fig. Fig. 11: Remove the cover seal using tool J-9256 or its equivalent6-cylinder 258 engine

  1. Remove the drive belts, engine fan and hub assembly, the accessory pulley, and vibration damper.
  2.  
  3. Remove the oil pan to timing chain cover screws and the screws that attach the cover to the block.
  4.  
  5. Raise the timing chain cover just high enough to detach the retaining nibs of the oil pan neoprene seal from the bottom side of the cover. This must be done to prevent pulling the seal end tabs away from the tongues of the oil pan gaskets which would cause a leak.
  6.  
  7. Remove the timing chain cover and gasket from the engine.
  8.  
  9. Use a razor blade to cut off the oil pan seal end tabs flush with the front face of the cylinder block and remove the seal. Clean the timing chain cover, oil pan, and cylinder block surfaces.
  10.  

To install:
  1. Apply seal compound (Perfect Seal, or equivalent) to both sides of the replacement timing case cover gasket and position the gasket on cylinder block.
  2.  
  3. Cut the end tabs off the replacement oil pan gasket corresponding to the pieces cut off the original gasket. Cement these pieces on the oil pan.
  4.  
  5. Coat the oil pan seal end tabs generously with Permatex® No. 2 or equivalent, and position the seal on the timing case cover.
  6.  
  7. Position the timing case cover on the engine. Place the timing case cover alignment tool and seal installer J-22248 or its equivalent in the crankshaft opening of the cover.
  8.  
  9. Install the cover-to-block screws and oil pan-to-cover screws. Tighten the cover-to-block screws to 60 inch lbs. and the oil pan-to-cover screws to 11 ft. lbs.
  10.  
  11. Remove the cover aligning tool and position the replacement oil seal aligning tool in the case. Position the replacement oil seal on the tool with the seal lip facing outward. Apply a light film of perfect seal, or equivalent, on the outside diameter of the seal.
  12.  
  13. Insert the draw screw from Tool J-9163 or its equivalent into the seal installing tool. Tighten the nut against the tool until the tool contacts the cover.
  14.  
  15. Remove the tools and apply a light film of engine oil to the seal lip.
  16.  
  17. Install the vibration damper and tighten the retaining screw to 80 ft. lbs.
  18.  
  19. Install the damper pulley. Tighten the capscrews to 20 ft. lbs.
  20.  
  21. Install the engine fan and hub assembly.
  22.  
  23. Install the drive belt(s).
  24.  

COVER INSTALLED
  1. Remove the drive belts.
  2.  
  3. Remove the vibration damper pulley.
  4.  
  5. Remove the vibration damper.
  6.  
  7. Remove the oil seal with Tool J-9256 or its equivalent.
  8.  
  9. Position the replacement oil seal on the timing case cover alignment tool and seal installer J-22248 or its equivalent with the seal lip facing outward. Apply a light film of perfect seal, or equivalent, to the outside diameter of the seal.
  10.  
  11. Insert the draw screw from Tool J-9163 into the seal installing tool. Tighten the nut against the tool until the tool contacts the cover.
  12.  
  13. Remove the tools. Apply a light film of engine oil to the seal lip.
  14.  
  15. Install the vibration damper and tighten the retaining bolt to 80 ft. lbs.
  16.  
  17. Install the damper pulley. Tighten the capscrews to 20 ft. lbs.
  18.  
  19. Install the drive belt(s).
  20.  

8-304, 360 and 401 Engines See Figures 12 through 23

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Fig. Fig. 12: Exploded view of the timing cover assembly and related components on V8 models through 1976; 1977 models are similar except for seal location



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Fig. Fig. 13: Remove the cooling fan retaining bolts ...



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Fig. Fig. 14: ... then remove the cooling fan



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Fig. Fig. 15: Remove the water pump pulley from the vehicle



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Fig. Fig. 16: Loosen the crankshaft pulley retaining bolts ...



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Fig. Fig. 17: ... then remove the pulley from the harmonic balancer



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Fig. Fig. 18: Remove the retaining bolt from the harmonic balancer



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Fig. Fig. 19: Install a puller on the harmonic balancer ...



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Fig. Fig. 20: ... then remove the balancer from the engine



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Fig. Fig. 21: Remove the timing chain cover bolts ...



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Fig. Fig. 22: ... then separate the cover from the engine block using a prytool



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Fig. Fig. 23: Remove the timing cover from the engine

  1. Remove the negative battery cable.
  2.  
  3. Drain the cooling system and disconnect the radiator hoses and by-pass hose.
  4.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove all of the drive belts and the fan and spacer assembly.
  2.  
  3. Remove the alternator and the front portion of the alternator bracket as an assembly.
  4.  
  5. Disconnect the heater hose.
  6.  
  7. Remove the power steering pump and/or the air pump, and the mounting bracket as an assembly. Do not disconnect the power steering hoses.
  8.  
  9. Remove the distributor cap and note the position of the rotor. Remove the distributor. Refer to the distributor removal and installation procedure earlier in this manual.
  10.  
  11. Remove the fuel pump.
  12.  
  13. Remove the vibration damper and pulley.
  14.  
  15. Remove the two front oil pan bolts and the bolts which secure the timing chain cover to the engine block.
  16.  

The timing gear cover retaining bolts vary in length and must be installed in the same locations from which they were removed.

  1. Remove the cover by pulling forward until it is free of the locating dowel pins.
  2.  

To install:
  1. Clean the gasket surface of the cover and the engine block.
  2.  
  3. Pry out the original seal from inside the timing chain cover and clean the seal bore.
  4.  
  5. Drive the new seal into place from the inside with a block of wood until it contacts the outer flange of the cover.
  6.  
  7. Apply a light film of motor oil to the lips of the new seal.
  8.  
  9. Before reinstalling the timing gear cover, remove the lower locating dowel pin from the engine block. The pin is required for correct alignment of the cover and must either be reused or a replacement dowel pin installed after the cover is in position.
  10.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Cut both sides of the oil pan gasket flush with the engine block with a razor blade.
  2.  
  3. Trim a new gasket to correspond to the amount cut off at the oil pan.
  4.  
  5. Apply sealer to both sides of the new gasket and install the gasket on the timing case cover.
  6.  
  7. Install the new front oil pan seal.
  8.  
  9. Align the tongues of the new oil pan gasket pieces with the oil pan seal and cement them into place on the cover.
  10.  
  11. Apply a bead of sealer to the cutoff edges of the original oil pan gaskets.
  12.  
  13. Place the timing case cover into position and install the front oil pan bolts. Tighten the bolts slowly and evenly until the cover aligns with the upper locating dowel.
  14.  
  15. Install the lower dowel through the cover and drive it into the corresponding hole in the engine block.
  16.  
  17. Install the cover retaining bolts in the same locations from which they were removed. Tighten to 25 ft. lbs.
  18.  
  19. Assemble the remaining components in the reverse order of removal.
  20.  

 
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