Front Cover and Timing Chain

Removal

  1. Disconnect and remove batteries and tray.
  2. Drain engine coolant.
  3. Remove radiator upper and lower hoses.
  4. Loosen crankshaft pulley belts.
  5. Remove left and right splash shields.
  6. Disconnect hood harness then remove hood with aid of helper. Place hinge pins in hinges after removal to avoid losing them.
  7. Remove air conditioning condenser and power steering fluid cooler. Then remove radiator and fan shroud (Figure 2-13).
    Figure 2-13: Radiator and Shroud Removal/Installation

    Figure 2-13: Radiator and Shroud Removal/Installation

     

     

  8. Loosen and remove serpentine drive belt. Use 1/2 in. drive breaker bar to rotate belt tensioner counterclockwise to loosen belt (Figure 2-7).
    Figure 2-7 Serpentine Belt Tensioner Location

    Figure 2-7: Serpentine Belt Tensioner Location

     

  9. Disconnect heater, bypass and inlet tube/hose at water pump and coolant crossover (Figure 2-14).
    Figure 2-14: Crossover Tube/Hose Connections

    Figure 2-14: Crossover Tube/Hose Connections

     

     

  10. Remove oil filler neck and coolant crossover (Figure 2-14).
  11. Remove fan and fan clutch.
  12. Remove crankshaft pulley (Figure 2-6).
    Figure 2-6 Crankshaft Pulley Mounting

    Figure 2-6: Crankshaft Pulley Mounting

     

  13. Remove torsional damper attaching bolt and washer (Figure 2-9).
    Figure 2-9 Torsional Damper and Crankshaft Pulley

    Figure 2-9: Torsional Damper and Crankshaft Pulley

     

  14. Remove torsional damper with tool 5740755 (Figure 2-10).
    Figure 2-10 Torsional Damper Removal

    Figure 2-10 Torsional Damper Removal

     

  15. Remove drive keys from crankshaft. Replace keys if worn, chipped, or distorted.
  16. Remove water pump and adapter plate as assembly (Figure 2-15).
    Figure 2-15: Water Pump and Adapter Plate Removal/Installation

    Figure 2-15: Water Pump and Adapter Plate Removal/Installation

     

  17. Remove bolts that attach front cover to oil pan (Figure 2-16).
    Figure 2-16: Drive Gear, Baffle, and Front Cover Removal

    Figure 2-16: Drive Gear, Baffle, and Front Cover Removal

     

  18. Rotate crankshaft until timing marks on sprockets and gears are aligned and number one piston is at TDC.
  19. Remove injection pump driven gear (Figure 2-16).
  20. Remove baffle from front cover (Figure 2-16).
  21. Remove nuts and washers attaching fuel injection pump to studs on front cover (Figure 2-16). NOTE: There are timing marks on the front cover and injection pump. Note position of these marks for installation reference.
  22. Remove bolts that attach front cover to engine block. Then break sealer bead with putty knife and remove cover.
  23. Cover oil pan opening to prevent dirt entry.
  24. Check timing chain deflection with dial indicator. Measure deflection mid-way between crankshaft and cam sprockets. Maximum allowable deflection is 0.810 in. (20.5 mm). Replace chain and sprockets if deflection is greater than specified.
  25. Check camshaft end play with dial indicator. Maximum allowable end play is 0.012 in. (0.3 mm). Replace cam thrust plate and spacer if end play is greater than specified. NOTE: Note position of timing marks on drive gear and
    crank and cam sprocket for installation reference.
  26. Remove bolt and washer attaching injection pump drive gear to camshaft. Then remove gear (Figure 2-17).
    Figure 2-17: Drive Gear, Timing Chain, and Sprocket Removal

    Figure 2-17: Drive Gear, Timing Chain, and Sprocket Removal

     

  27. Slide timing chain and sprockets off camshaft and crankshaft (Figure 2-17).
  28. Remove drive keys from camshaft and crankshaft.
  29. Replace keys if chipped, cracked, or distorted.
  30. Minor burrs can be removed with a stone or fine tooth file.
  31. Clean all old sealer off engine block, front cover, and water pump/adapter plate with scraper.

Installation

  1. Install new camshaft thrust plate and spacer if required.
  2. Clean front cover and engine block sealing surfaces with carb cleaner and wipe dry.
  3. Install drive keys in camshaft and crankshaft. Be sure keys are seated.
  4. Assemble and install timing chain and sprockets (Figure 2-18). Check timing mark alignment before proceeding.
    Figure 2-18: Timing Chain, Sprockets, and Drive Gear Installation

    Figure 2-18: Timing Chain, Sprockets, and Drive
    Gear Installation

     

  5. Install injection pump drive gear on camshaft (Figure 2-18). Timing mark on gear should be facing upward (12 o’clock position). Then install drive gear attaching washer and bolt. Tighten bolt to 55-60 lb-ft (75- 81 N•m) torque.
  6. Install new seal in front cover with tool 5740754.
  7. Apply sealer to front cover as follows:
    1. Use anaerobic sealer, such as Loctite 510, on cover surfaces that contact engine block and on engine block.
    2. Use RTV-type sealer, such as Loctite 592, on oil pan and oil pan contact surface of front cover.
    3. Refer to Figure 2-19 for sealer application diagram.
      Figure 2-19: Front Cover Sealer Application Diagram

      Figure 2-19: Front Cover Sealer Application
      Diagram

       

  8. Install front cover on engine block (Figure 2-20). Be sure cover is fully seated on engine block dowels, engine block, and oil pan, before installing cover bolts.
    Figure 2-20: Front Cover Mounting

    Figure 2-20: Front Cover Mounting

     

  9. Install front cover attaching bolts. Then tighten bolts as follows:
    1. Tighten cover-to-engine block bolts to 33 lb-ft (45 N•m) torque.
    2. Tighten oil pan-to-front cover bolts to 4-10 lb-ft (5-14 N•m) torque.
  10. Install injection pump gasket on front cover studs (Figure 2-20).
  11. Install baffle in front cover (Figure 2-21). Maintain minimum clearance of 0.040 in. (1.02 mm) between baffle and injection pump drive gear. Tighten baffle attaching bolts/nuts to 33 lb-ft (45 N•m) torque.
    Figure 2-21: Baffle and Pump Driven Gear Installation

    Figure 2-21: Baffle and Pump Driven Gear
    Installation

     

  12. Install fuel injection pump driven gear on pump shaft as
    follows:

    1. Align timing marks on drive and driven gears and install driven gear on pump shaft.
    2. Verify timing mark alignment. Drive gear mark should be at 12 o’clock position and driven gear mark at 6 o’clock position. NOTE: If timing marks are not perfectly aligned, turn the pump shaft to correct alignment. Do not turn the gears.
    3. Install and tighten driven gear attaching bolts to 13-20 lb-ft (18-27 N•m) torque.
  13. Check alignment of timing marks on front cover and injection pump flange. Rotate pump to align if necessary. Then install pump attaching nuts.
  14. Secure fuel injection pump to front cover. Tighten pump attaching nuts to 13-20 lb-ft (18-27 N•m) torque.
  15. Lubricate front cover seal lip with engine oil, or petroleum jelly. Then lubricate seal contact surface of torsional damper with engine oil. Be sure seal contact surface of damper is smooth and free of burrs, nicks, or corrosion.
  16. Install damper drive key in crankshaft slot. Be sure key is fully seated.
  17. Install torsional damper. Then install damper attaching washer and bolt. Tighten bolt to 140-160 lb-ft (190-217 N•m) torque.
  18. Install crankshaft pulley. Tighten pulley bolts to 48 lb-ft (65 N•m) torque.
  19. Install coolant crossover and oil filler neck. Tighten crossover bolts to 31 lb-ft (42 N•m) torque and filler neck attaching nut to 13-20 lb-ft (18-27 N•m) torque.
  20. Apply bead of anaerobic sealer, such as Loctite 510, to water pump and adapter plate. Refer to Figure 2-22 for sealer application.
    Figure 2-22: Water Pump Adapter Plate Sealer Application Diagram

    Figure 2-22: Water Pump Adapter Plate Sealer
    Application Diagram

     

  21. Install water pump and adapter plate. Apply Permatex/Loctite pipe sealing compound, to fastener that goes in hole “A” (Figure 2-22). Tighten pump/adapter bolts to 13-20 lb-ft (18-27 N•m) torque.
  22. Install fan pulley fan, and fan clutch. Tighten attaching nuts to 15-20 lb-ft (20-27 N•m).
  23. Install and adjust serpentine drive belt.
  24. Connect heater and bypass hoses at water pump and crossover. Then attach radiator upper inlet hoses to inlet tube.
  25. Install radiator and shroud (Figure 2-13). Then install air conditioning condenser and power steering fluid cooler.
  26. Connect radiator upper and lower hoses.
  27. Fill cooling system.
  28. Connect battery negative cables.
  29. Evacuate and recharge air conditioning system if necessary.
  30. Start and run engine to verify proper operation. Purge air from cooling system (if necessary), and top off coolant level at surge tank.

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