REMOVAL & INSTALLATION
See Figures 1 and 2
- Disconnect the negative battery cable.
- Remove the engine and transaxle assembly from the vehicle and position in a suitable holding fixture. Remove the dipstick.
- If equipped, remove the accessory drive pulley. Remove the crankshaft pulley attaching bolt and washer, then remove the pulley.
- Using Front Seal Remover T74P-6700-A or equivalent, remove the timing/front cover oil seal.
- Remove the front cover attaching bolts from front cover. Pry the top of the front cover away from the block.
- Clean all dirt and old gasket material from all mating surfaces.
- Remove the oil pan.
- Clean and inspect all parts before installation. Make sure that the cylinder block and front cover are free of old gasket material and/or dirt.
- Apply oil resistant sealer to a new front cover gasket, then position the gasket into front cover.
- With the front oil seal removed, position the front cover on the engine.
- Position front cover alignment tool T84P-6019-C or equivalent, onto the end of the crankshaft, ensuring the crank key is aligned with the keyway in the tool. Bolt the front cover to the engine and tighten the bolts to 6-8 ft. lbs. (8-11 Nm). Remove the front cover alignment tool.
- Install a new front cover oil seal using Pinion Oil Seal Installer T83T-4676-A, or equivalent suitable seal installer. Lubricate the hub of the crankshaft pulley with polyethylene grease to prevent damage to the seal during installation and initial engine start.
- Install the crankshaft pulley.
- Install the oil pan.
- If equipped, install the accessory drive pulley.
- Install crankshaft pulley attaching bolt and washer. Tighten to 140-170 ft. lbs. (190-230 Nm).
- Install the engine and transaxle assembly in the vehicle. Connect the negative battery cable.
See Figures 3, 4, 5, 6 and 7
- Disconnect the negative battery cable. Properly drain the engine cooling system.
- Loosen the four water pump pulley bolts while the water pump drive belt is in place.
- Loosen the alternator belt-adjuster jackscrew to provide enough slack in the alternator drive belt for removal.
- Using a 1 / 2 in. drive breaker bar, rotate the automatic belt tensioner down and to the left or right (depending upon application) to remove the water pump drive belt.
- Remove the lower radiator hose and the heater hose from the water pump.
Remove the crankshaft pulley and damper:
- If necessary, raise and safely support the vehicle, then remove the right-hand front wheel and tire assembly.
- Remove the four crankshaft pulley-to-damper retaining bolts, then remove the crankshaft pulley.
- Remove the crankshaft damper retaining bolt and washer.
- Remove the damper using Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B.
- Remove the timing cover/crankshaft front seal from the engine front cover using Jet Plug Remover T77L-9533-B.
- Disengage the engine control sensor wiring from the crankshaft position (CKP) sensor and locating stud bolt (Flexible Fuel (FF) only).
- Drain and remove the oil pan.
- Remove the water pump pulley retaining bolts and water pump pulley.
- Remove the retaining bolts from the timing cover to the block, then remove the timing cover.
The timing cover and water pump may be removed as an assembly by not removing bolts 11-15.
- Lightly oil all bolt and stud threads except those specifying special sealant.
Be careful when scraping the old gasket material from the timing/front cover because aluminum gouges easily, and if scratched, leakage may occur.
- Clean all old gasket material and sealer from the timing cover, oil pan and cylinder block.
- Inspect the timing cover seal for wear or damage, and replace if necessary.
- Align a new timing cover gasket over the cylinder block dowels.
- Install the timing cover/water pump assembly onto the cylinder block with the water pump pulley loosely attached to the water pump hub.
- Apply pipe sealant to bolt numbers 1, 2 and 3 and hand start them along with the rest of the cover retaining bolts. Tighten bolts 1-10 to 15-22 ft. lbs. (20-30 Nm) and 11-15 to 71-106 inch lbs. (8-12 Nm).
- Install the oil pan and tighten the retaining bolts to 9 ft. lbs. (12 Nm).
- Hand tighten the water pump pulley retaining bolts.
Install the crankshaft damper and pulley:
- Lubricate the oil seal with clean oil, then install the seal suing Vibration Damper and Seal Replacer T82L-6316-A and Front Cover Replacer T70P.
- Coat the crankshaft damper sealing surface with clean engine oil. Apply Silicone Rubber D6AZ-19562-AA or BA to the keyway of the damper before installation. Install the damper using Vibration Damper and Seal Replacer T82L-6316-A.
- Install the damper retaining bolt and washer. Tighten to 93-121 ft. lbs. (125-165 Nm).
- Install the crankshaft pulley, then install the four retaining bolts. Tighten the bolts to 30-44 ft. lbs. (40-60 Nm).
- If removed, install the right-hand wheel and tire assembly, then carefully lower the vehicle.
- Install the automatic belt tensioner. Tighten the two retaining nuts and bolt to 35 ft. lbs. (48 Nm).
- Install the water pump and accessory drive belts. Torque the water pump pulley retaining bolts to 15-22 ft. lbs. (20-30 Nm).
- Install the lower radiator hose and the heater hose and tighten the clamps.
- Fill the crankcase with the correct amount and type of engine oil. Connect the negative battery cable. Fill and bleed the cooling system.
- Start the engine and check for coolant and oil leaks.
See Figure 8
- Disconnect the negative battery cable. Properly drain the cooling system and the engine oil.
- Remove the air cleaner assembly and air intake duct.
- If necessary, remove the fan shroud attaching screws and bolts, then remove the fan/clutch assembly and shroud.
- Loosen the accessory drive belt idler. Remove the drive belt and water pump pulley.
- Remove the power steering pump mounting bracket attaching bolts. Leaving the hoses connected, place the pump/bracket assembly in a position that will prevent the loss of power steering fluid.
- If equipped with air conditioning, remove the compressor front support bracket. Leave the compressor in place.
- Disconnect coolant bypass and heater hoses at the water pump. Disconnect the radiator upper hose at the thermostat housing.
- Disconnect the coil wire from the distributor cap, then remove the cap with the secondary wires still attached. Remove the distributor retaining clamp and lift distributor out of the front cover.
- Raise and safely support the vehicle.
- Remove the crankshaft damper and pulley.
If the crankshaft pulley and vibration damper have to be separated, mark the damper and pulley so they may be reassembled in the same relative position. This is important as the damper and pulley are initially balanced as a unit. If the crankshaft damper is being replaced, check if the original damper has balance pins installed. If so, new balance pins (E0SZ-6A328-A or equivalent) must be installed on the new damper in the same position as the original damper. The crankshaft pulley must also be installed in the original installation position.
- Remove the oil filter, the disconnect the radiator lower hose at the water pump.
- Remove the oil pan. For details, please refer to the procedure located earlier in this section.
- Lower the vehicle.
- Remove the front cover attaching bolts.
Do not overlook the cover attaching bolt located behind the oil filter adapter. The front cover will break if pried upon and all of the attaching bolts are not removed.
- Remove the ignition timing indicator.
- Remove the front cover and water pump as an assembly. Remove the cover gasket and discard.
The front cover houses the oil pump. If a new front cover is to be installed, remove the water pump and oil pump from the old front cover.
- Lightly oil all bolt and stud threads before installation. Clean all gasket surfaces on the front cover, cylinder block and fuel pump. If reusing the front cover, replace crankshaft front oil seal.
If a new front cover is to be installed, complete the following:
- Install the oil pump gears.
- Clean the water pump gasket surface. Position a new water pump gasket on the front cover and install the water pump. Install the pump attaching bolts and tighten to 15-22 ft. lbs. (20-30 Nm).
- Install the distributor drive gear.
- Lubricate the crankshaft front oil seal with clean engine oil.
- Position a new cover gasket on the cylinder block and install the front cover/water pump assembly using dowels for proper alignment. A suitable contact adhesive is recommended to hold the gasket in position while the front cover is installed.
- Position and install the ignition timing indicator.
- Install the front cover attaching bolts. Apply Loctite® or equivalent, to the threads of the bolt installed below the oil filter housing prior to installation. This bolt is to be installed and tightened last. Tighten all bolts to 15-22 ft. lbs. (20-30 Nm).
- Raise the vehicle and support safely.
- Install the oil pan. Connect the radiator lower hose. Install a new oil filter.
- Coat the crankshaft damper sealing surface with clean engine oil.
- Position the crankshaft pulley key in the crankshaft keyway.
- Install the damper with damper washer and attaching bolt. Tighten the bolt to 103-132 ft. lbs. (140-179 Nm).
- Install the crankshaft pulley and tighten the attaching bolts 19-28 ft. lbs. (26-38 Nm).
- Lower the vehicle.
- Connect the coolant bypass hose.
- Install the distributor with rotor pointing at No. 1 distributor cap tower. Install the distributor cap and coil wire.
- Connect the radiator upper hose at thermostat housing.
- Connect the heater hose.
- If equipped with air conditioning, install compressor and mounting brackets.
- Install the power steering pump and mounting brackets.
- Position the accessory drive belt over the pulleys.
- Install the water pump pulley. Position the accessory drive belt over water pump pulley and tighten the belt.
- Connect the negative battery cable. Fill the crankcase and cooling system to the proper level.
- Install the air cleaner assembly and air intake duct.
- Start the engine and check for leaks.
- Check the ignition timing and adjust as required.