NOTE: This section includes removal and installation of the timing chain, its related sprockets, the front cover and seals. Review this entire procedure to determine which steps are specifically related to those components being serviced.
To Remove:
- Before servicing the vehicle, refer to the precautions in the beginning of this section. You may need adapter tool (205-072) for this procedure.
- Disconnect the negative battery cable.
- Remove the cooling belt fan and shroud.
- Remove the serpentine drive belt and belt tensioner.
- Remove the valve cover.
- Remove the crankshaft pulley.
- Set the No. 1 piston to TDC and install the camshaft alignment plate (303-376).
- Remove the plug bolt to accesses the timing peg orifice.
- Install the crankshaft timing peg (303-507).
- Install the drive pinion holding fixture (205-126) on the crankshaft pulley.
- While holding the crankshaft in position, remove the crankshaft retaining bolt and the crankshaft pulley.
- If the crankshaft front oil seal is being serviced, remove the crankshaft front oil seal with a suitable pry bar.
CAUTION
Use care not to damage the engine front cover or the crankshaft when removing the seal.
- Remove the crankshaft position sensor (CKP).
- Remove the water pump pulley.
- Disconnect the power steering high-pressure and return hoses from the power steering pump. Remove the nylon O-ring from the high-pressure hose.
- Remove the four bolts that retain the power steering pump along with the power steering pump.
NOTE: This step is needed only if a new front cover is being installed.
- Using a three-jaw puller, remove the fan drive pulley.
NOTE: One of the front cover retaining bolts is located behind the cooling fan drive pulley. Remove this bolt by rotating the pulley so that one of the pulley access holes aligns with the bolt.
- Remove the engine front cover retaining bolts and the front cover.
- Remove the timing chain tensioner.
- Compress the timing chain tensioner, and insert a suitable pin into the retainer hole.
- Remove the bolts and the timing chain tensioner.
- Remove the right-hand timing chain guide and the timing chain.
- Remove the left-hand timing chain guide bolts and the guide.
CAUTION
Do not rely on the camshaft alignment plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
NOTE: When required, remove the camshaft sprocket retaining bolts sprockets. Use the flats on the camshaft to prevent camshaft rotation.
To Install:
- Remove the camshaft alignment plate (303-376).
CAUTION
Do not rotate the camshafts. Damage to the valves and pistons can occur.
NOTE: If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.
- Install the camshaft sprockets and bolts, if removed. Install the bolts loosely, but do not tighten at this time.
- Install the left-hand timing chain guide and bolts.
- Torque fasteners to 87 in-lb (10 Nm).
- Install the timing chain.
- Install the right-hand timing chain guide.
- Install the timing chain tensioner.
- Torque the fasteners to 89 in-lb (10 Nm).
- Remove the retaining pin to release the piston.
- Install the camshaft alignment plate.
CAUTION
Damage to the alignment plate or the camshafts can occur when the tool is used to prevent camshaft rotation. Use the flats on the camshafts to prevent camshaft rotation.
- Torque the camshaft retaining bolts to 48 ft-lb (65 Nm).
- If a new front cover is being installed, use a nut, bolt, and flat washer set-up to press the new fan drive pulley.
- Clean and inspect the mounting surfaces of the engine and the front cover.
NOTE: The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket material.
- Apply a 2.5 mm bead of silicone gasket material to the cylinder head and oil pan parting lines. Apply a 2.5 mm bead of silicone gasket material to the front cover.
| Front cover torque sequence-2.3L
|
- Install the front cover. Tighten the bolts following the proper sequence to the specified torque value:
- Step 1: Tighten the 8 mm bolts to 89 in-lb (10 Nm).
- Step 2: Tighten the 10 mm bolts to 18 ft-lb (25 Nm).
- Step 3: Tighten the 13 mm bolts to 35 ft-lb (48 Nm).
- If the crankshaft front oil seal is being serviced, lubricate the sealing surface of the crankshaft damper pulley with clean engine oil.
- Install the crankshaft front oil seal using the crankshaft front oil seal installer (303-096).
NOTE: Do not reuse the crankshaft pulley bolt.
- To install the crankshaft pulley, apply clean engine oil on seal contact area of the pulley before installing it.
- Install the crankshaft pulley and hand-tighten the bolt.
- Install an M-6 bolt to hold the crankshaft in position.
- Install the drive pinion holding the fixture on the crankshaft pulley.
- Tighten the crankshaft damper bolt in two steps:
- Step 1: Torque to 74 ft-lb (100 Nm).
- Step 2: Tighten the bolt an additional 90 degrees.
- Remove the M-6 bolt.
- Remove the crankshaft timing peg.
- Install the crankshaft timing plug.
- Torque to 15 ft-lb (20 Nm).
- Install the crankshaft position sensor. Install the bolts but do not tighten at this time.
- Adjust the crankshaft position sensor using the alignment tool.
- Torque the mounting fasteners to 62 in-lb (7 Nm).
- Connect the CKP sensor electrical connector.
- Remove the camshaft alignment plate tool.
- Install the valve cover. Tighten the bolts from the center out alternating left to right.
- Torque the bolts to 89 inch lbs. (10 Nm).
- Position the power steering pump.
- Torque the mounting bolts to 18 ft-lb (25 Nm).
- Connect the power steering return hose.
- Install the high-pressure power steering line with a new nylon O-ring.
- Torque to 15 ft-lb (20 Nm).
- Install the water pump pulley.
- Torque the retaining bolts to 18 ft-lb (25 Nm).
- Install the belt tensioner.
- Torque the fastener to 36 ft-lb (50 Nm).
- Install the serpentine belt.
- Install the cooling fan and shroud.
- Connect the negative battery cable.
- Start the engine. Check for leaks and repair as necessary.
