Timing Chain Cover and Seal

REMOVAL & INSTALLATION

2.6L Engine

CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

1. Relieve the fuel system pressure, and disconnect the negative battery cable.
2. Drain the cooling system and engine oil.
3. Remove the fan shroud and cooling fan.
4. Remove the cylinder head.
5. Remove the oil pan.

   Fig. 1: Timing chain and related components — 2.6L engine

6. Remove the drive belts.
7. Remove the water pump pulley.
8. Remove the alternator and bracket.
9. Remove the power steering pump and bracket.
10. Without disconnecting the A/C lines, remove the A/C compressor mounting bolts and remove the A/C compressor. Secure the compressor out of the way. Remove the bolts and the A/C compressor mounting bracket.
11. Remove the water pump.
12. Remove the coolant bypass pipe.
13. Remove the bolt, and by using a suitable puller, remove the crankshaft pulley.
14. Loosen the mounting bolts and remove the timing chain cover.

    To install:

15. Install the timing cover with a new gasket Torque the timing cover bolts to 14–19 ft. lbs. (19–25 Nm).
16. Install the crankshaft pulley.
17. Install the coolant bypass pipe.
18. Install the water pump.
19. Install the power steering pump bracket and the power steering pump.
20. Mount the A/C compressor bracket and install the A/C compressor.
21. Mount the alternator bracket and the alternator. Plug in the alternator wiring harness connector.
22. Install the water pump pulley.
23. Install the drive belts and adjust to specifications.
24. Install the oil pan.
25. Install the cylinder head.
26. Install the fan shroud and cooling fan.
27. Fill the crankcase with the proper type and quantity of engine oil. Fill and bleed the cooling system. Run the engine and check for leaks and proper operation.
28. Check the idle speed and ignition timing and adjust, if necessary.

3.0L Engine (B Series Pick-up)

NOTE: The A/C system must be discharged to remove the front cover. Have the A/C refrigerant reclaimed by a MVAC certified shop. The front seal can be serviced with the engine in the vehicle. Remove the crankshaft damper, then follow the seal replacement procedure under installation.

1. Disconnect the negative battery cable.
2. Drain the cooling system and crankcase.

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

3. Remove the cooling fan.
4. Loosen the water pump pulley bolts. Remove the accessory drive belts. Remove the water pump pulley.
5. Remove the alternator adjusting arm and brace assembly. Remove the heated air intake duct from the engine.
6. Remove the upper motor mount retaining nuts. Remove the A/C compressor upper bolts, then remove the front cover front nuts on vehicles with automatic transmission and A/C.
7. Raise the vehicle. Remove the A/C compressor bolts and bracket if so equipped and position the assembly aside.
8. Remove the crankshaft pulley and damper assembly. Remove the oil pan.

   NOTE: According to the manufacturer, you must remove the water pump to remove the cover. However, we have found that on some models and/or years the water pump can be left bolted to the cover, thereby reducing some of the labor. Try removing the cover with the water pump attached first.

9. Lower the vehicle. Remove the lower radiator hose. Remove the water pump.
10. If necessary, remove the crankshaft position sensor.

    Fig. 2: Front cover removal — 3.0L

    Fig. 3: Front cover bolt installation chart — 3.0L

11. Remove the timing cover to cylinder block attaching bolts. Carefully remove the timing cover from the cylinder block.
12. Inspect the oil seal. If the seal needs replacing, follow the procedures under installation.

    To install:

13. Clean timing cover and oil pan sealing surfaces. Clean and inspect all parts. The camshaft retaining bolt has a drilled oil passage for timing chain assembly lubrication. Clean oil passage with solvent. Do not replace with standard bolt.
14. Install timing cover assembly. Install retaining bolts with pipe sealant and tighten to 19 ft. lbs. (25 Nm). Refer to the illustration.
15. If the front seal needs to be replaced, proceed as follows:
    1. Using a front cover seal removal tool, or equivalent, remove the front seal.
    2. Lubricate the engine front cover and oil seal lip inner lip with engine oil.
    3. Using a seal driver/installation tool, install the new seal into the front cover.
16. If necessary, install the crankshaft position sensor.
17. Install oil pan and water pump. Refer to the necessary procedures in this section.
18. Install crankshaft damper and pulley assembly.
19. Install drive belt components. Install drive belts and adjust.
20. Fill crankcase. Refill and bleed cooling system. Connect the negative battery cable. Start engine check for coolant, oil and exhaust leaks.

4.0L Engine

NOTE: Review the complete service procedure before starting this repair. Refer to the necessary service procedures in this section. The front seal can be serviced with the engine in the vehicle. Remove the crankshaft damper, then follow the seal replacement procedure under installation.

1. Disconnect the negative battery cable. Remove/lower the oil pan.
2. Drain the cooling system.

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

   Fig. 4: To remove the front cover, remove the fan, shroud and unbolt the front cover-to-accessory bracket brace . . .

   Fig. 5: . . . then remove the brace. Also remove the damper and any other obstructions to the cover

3. Remove the engine fan and shroud.
4. Remove the air conditioning compressor and position it out of the way. DO NOT disconnect the refrigerant lines!
5. Remove the power steering pump and position it out of the way. DO NOT disconnect the hoses!
6. Remove the alternator.
7. Remove the water pump.
8. Remove the drive pulley/damper from the crankshaft.
9. Remove the crankshaft timing sensor.

   Fig. 6: Front cover mounting — 4.0L engine

   Fig. 7: Remove the front cover attaching bolts

   Fig. 8: Don't forget about the oil pan-to-front cover attaching bolts!

10. Remove the front cover attaching bolts. It may be necessary to tap the cover loose with a plastic mallet.
11. Inspect the oil seal. If the seal needs replacing, follow the procedures under installation.

    To install:

    Fig. 9: Remove the old gaskets and thoroughly clean all of the mating surfaces

12. Thoroughly clean all of the gasket and sealing surfaces and remove all traces of the old gaskets, oil, grease and/or dirt. Use new gaskets and apply a thin layer of sealant/adhesive to them.

    NOTE: If the specialized tools aren't available, the front seal can be replaced using normal hand tools. Before installing the cover, use a punch to carefully knock the old seal out of the cover, and a seal driver to seat the new seal.

    Fig. 10: Place the cover on a bench and carefully knock the old seal out of the cover using a hammer and punch

    Fig. 11: Use an ordinary seal driver, and seat a new seal into the cover at the same position as the old one

13. Install the front cover and attaching bolts. Tighten the bolts to 13–15 ft. lbs. (17–21 Nm). Refer to the illustration.
14. If the front seal needs to be replaced, proceed as follows:
    1. Using a seal removal tool, remove the front seal.
    2. Lubricate the engine front cover and oil seal lip inner lip with engine oil.
    3. Using a seal driver/installation tool, install the new seal into the front cover.
15. Install the crankshaft timing sensor.
16. Install the drive pulley/damper.
17. Install the water pump.
18. Install the fan.
19. Install the alternator.
20. Install the power steering pump.
21. Install the air conditioning compressor.
22. Install the oil pan.
23. Fill the cooling system.
24. Fill the crankcase with the proper grade and amount of engine oil. Connect the negative battery cable. Start the engine and check for leaks, then roadtest the vehicle for proper operation.