Front Engine Plate: Service and Repair
ENGINE FRONT COVER REMOVAL / INSTALLATIONRemoval
1. Disconnect the negative battery cable.
2. Remove the fan and shroud.
3. Remove the drive belt.
4. Remove the valve cover.
5. Set No. 1 piston to TDC and install the Camshaft Alignment Plate 303-376.
6. Remove the plug for the crankshaft timing peg.
7. Install the Crankshaft Timing Peg 303-507.
8. Install an M6 bolt into the crankshaft pulley to verify the engine timing.
9. Remove the bolt and the camshaft pulley.
10. Disconnect the crankshaft position sensor.
11. Remove the crankshaft position sensor.
12. Remove the belt tensioner.
13. Remove the water pump pulley.
14. Disconnect the power steering high pressure hose. Remove the nylon O-ring.
15. Disconnect the power steering return hose.
16. Remove the bolt and the power steering pump.
Note: This step is needed only if a new front cover is being installed.
17. Using a three-jaw puller, remove the fan drive pulley.
Caution: There is one bolt behind the cooling fan drive pulley. This bolt can be accessed by lining up one of the holes in the pulley with the bolt.
18. Remove the bolts and the engine front cover.
Installation
Note: This step is needed only if a new front cover is being installed.
1. Install the fan drive pulley using a nut and bolt with flat washers.
2. 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 and sealant.
3. Apply a 2.5 mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
4. Install the front cover. Tighten the bolts in the sequence shown, to the following specifications:
1. Tighten the 8 mm bolts to 10 Nm (1 kgf-m, 7 lbs.).
2. Tighten the 10 mm bolts to 25 Nm (2.5 kgf-m, 18 lbs.).
3. Tighten the 13 mm bolts to 48 Nm (4.889 kgf-m, 35 lbs.).
5. Position the power steering pump and install the lower retaining bolt.
6. Connect the power steering return hose.
7. Install a new nylon O-ring and install the high pressure line.
8. Install the water pump pulley.
9. Install the belt tensioner.
Note: Do not reuse the crankshaft damper bolt.
10. Install the crankshaft pulley and hand-tighten the bolt.
11. Install an M6 bolt in the crankshaft pulley. Tighten the crankshaft retaining bolt in two stages.
1. Stage 1: Tighten to 40 Nm (4.1 kgf-m, 30 lbs.).
2. Stage 2: Rotate the bolt an additional 90 degrees.
12. Install the crankshaft position sensor, do not tighten the bolts at this time.
13. Adjust the crankshaft position sensor with the Alignment Tool, and tighten the mounting bolts.
14. Connect the crankshaft position sensor electrical connector.
15. Remove the M6 bolt from the crankshaft pulley.
16. Remove the Crankshaft Timing Peg 303-507.
17. Install the plug.
18. Remove the Camshaft Alignment Plate 303-376.
19. Install the valve cover.
20. Install the drive belt.
21. Install the fan and shroud.
22. Connect the battery ground cable.