Removal & Installation
2.0L (VIN N) & 2.3L (VIN Z) Engine
Before servicing the vehicle, refer to the Precautions section.
NOTEThe 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. Therefore the engine must be retimed each time the damper is removed, otherwise severe engine damage can occur.
- Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
Remove or disconnect the following:
Accessory drive belt
Position the engine so that the number 1 piston is at top dead center (TDC).
WARNINGFailure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
- Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
Install special tool 303-465 (or a suitable DOHC camshaft alignment tool) to maintain alignment between the two camshafts.
WARNINGThe special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
NOTEThe camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
- Remove the plug bolt.
Install special tool 303-507 or a suitable peg to prevent engine rotation.
NOTESpecial tool 303-507 will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.
WARNINGFailure to hold the crankshaft pulley in place during bolt loosening can result in damage to the engine.
- Install special tools 205-126 and 205-072-02 or a suitable crankshaft pulley holder to prevent the engine from turning.
- Remove the crankshaft pulley bolt.
- Remove the special tools.
Remove the crankshaft pulley.
- Apply clean engine oil on the seal area before installing.
Install the crankshaft pulley and hand-tighten the bolt.
WARNINGOnly hand-tighten the bolt or damage to the front cover can occur.
NOTEThis step will correctly align the crankshaft pulley to the crankshaft.
- 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.
Rotate the pulley as necessary to align the bolt holes.
WARNINGFailure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages:
Stage 1: Tighten to 74 ft. lbs. (100 Nm)
- Remove the special tools.
- Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
Remove special tool 303-507, camshaft holder.
NOTEOnly turn the engine in the normal direction of rotation.
- Turn the engine two complete revolutions.
- Turn the crankshaft until the No. 1 piston is at top dead center (TDC).
- Install the plug bolt and tighten to 15 ft. lbs. (20 Nm)
- Install the valve cover.
- Install the accessory drive belt.
- Reconnect the negative battery cable.