REMOVAL & INSTALLATION
See Figures 1 and 2
- Remove the engine and transaxle from the vehicle as an assembly and position in a suitable holding fixture. Remove the dipstick.
- Remove accessory drive pulley, if equipped, Remove the crankshaft pulley attaching bolt and washer and remove pulley.
- Remove front cover attaching bolts from front cover. Pry the top of the front cover away from the block.
- Clean any gasket material from the surfaces.
- Check timing chain and sprockets for excessive wear. If the timing chain and sprockets are worn, replace with new.
- Check timing chain tensioner blade for wear depth. If the wear depth exceeds specification, replace tensioner.
- Turn engine over until the timing marks are aligned. Remove camshaft sprocket attaching bolt and washer. Slide both sprockets and timing chain forward and remove as an assembly.
- If equipped, check timing chain vibration damper for excessive wear. Replace if necessary; the damper is located inside the front cover.
- Remove the oil pan. For details, please refer to the procedure regarding this procedure.
- Clean and inspect all parts before installation. Clean the oil pan, cylinder block and front cover of gasket material and dirt.
- Slide both sprockets and timing chain onto the camshaft and crankshaft with timing marks aligned. Install camshaft bolt and washer and tighten to 41-56 ft. lbs. (56-76 Nm). Oil timing chain, sprockets and tensioner after installation with clean engine oil.
- Apply oil resistant sealer to a new front cover gasket and position gasket into front cover.
- Remove the front cover oil seal and 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 a 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 crankshaft pulley.
- Install the oil pan.
- Install the accessory drive pulley, if equipped.
- Install crankshaft pulley attaching bolt and washer. Tighten to 140-170 ft. lbs. (190-230 Nm).
- Remove engine from work stand and install in vehicle.
See Figures 3 and 4
- Disconnect the negative battery cable. Drain the cooling system and crankcase. Remove the crankshaft pulley and front cover assemblies.
- Rotate the crankshaft until the No. 1 piston is at the TDC on its compression stroke and the timing marks are aligned.
- Remove the camshaft sprocket attaching bolt and washer. Slide both sprockets and timing chain forward and remove as an assembly.
- Check the timing chain and sprockets for excessive wear. Replace if necessary.
Before installation, clean and inspect all parts. Clean the gasket material and dirt from the oil pan, cylinder block and front cover.
- Slide both sprockets and timing chain onto the camshaft and crankshaft with the timing marks aligned. Install the camshaft bolt and washer and torque to 37-51 ft. lbs. (50-70 Nm). Apply clean engine oil to the timing chain and sprockets after installation.
The camshaft bolt has a drilled oil passage in it for timing chain lubrication. If the bolt is damaged, do not replace it with a standard bolt.
- Install the timing cover and the crankshaft pulley and damper. Tighten the crankshaft damper bolt to 93-121 ft. lbs. (126-164 Nm) and the pulley bolts to 30-44 ft. lbs. (41-60 Nm).
- Fill the crankcase with the proper type and quantity of oil. Fill and bleed the engine cooling system.
- Connect the negative battery cable, then start the engine and check for coolant, oil and exhaust leaks.
See Figures 5, 6 and 7
- Disconnect the negative battery cable. Drain the cooling system and crankcase.
- Remove the timing chain/engine front cover and water pump as an assembly. For details, please refer to the timing chain cover procedure located earlier in this section.
- Remove the camshaft sprocket bolt and washer from end of the camshaft.
- Remove the distributor drive gear.
- Remove the camshaft sprocket, crankshaft sprocket and timing chain.
If the crankshaft sprocket is difficult to remove, carefully pry to sprocket off of the shaft using a pair of large prybars positioned on both sides of the crankshaft sprocket.
- Remove the chain tensioner assembly from the front of the cylinder block. This is accomplished by pulling back on the ratcheting mechanism and installing a pin through the hole in the bracket to relieve tension.
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 water pump. Install the pump attaching bolts and tighten to 15-22 ft. lbs. (20-30 Nm).
- Rotate the crankshaft as necessary to position piston No. 1 at TDC and the crankshaft keyway at the 12 o' clock position.
- Install the tensioner assembly. Make sure the ratcheting mechanism is in the retracted position with the pin pointing outward from the hole in the bracket assembly. Tighten the retaining bolts to 6-10 ft. lbs. (8-14 Nm).
- Lubricate timing chain with clean engine oil. Install the camshaft sprocket, crankshaft sprocket and timing chain.
- Remove the pin from the tensioner/vibration damper assembly to load the timing chain vibration damper arm against the timing chain. Make certain the timing marks are positioned across from each other.
- Install the distributor drive gear.
- Install the camshaft sprocket washer and bolt at the end of the camshaft, then tighten to 30-37 ft. lbs. (41-50 Nm).
- Install the timing chain/engine front cover, using a new gasket. For details regarding this procedure, please refer to timing chain cover removal and installation earlier in this section.
- Connect battery ground cable. Start the engine and check for leaks.