Installing Timing Chain Cover With Oil Pan On

Installing a timing chain cover with the oil pan still attached to the engine can be a challenging task, but it's not impossible. This procedure is often necessary when replacing a leaking timing cover gasket or performing other front engine repairs without removing the entire oil pan. While it's generally easier to install the timing cover with the oil pan removed, there are techniques to accomplish this job with the pan in place.

The main difficulty lies in properly seating the lower oil seal between the timing cover and oil pan. However, with the right approach and some patience, you can successfully install a timing chain cover without removing the oil pan. This guide will walk you through the process step-by-step, providing tips and tricks to make the job easier.

Preparation and Tools Required

Before attempting to install the timing chain cover with the oil pan on, it's crucial to gather all the necessary tools and materials. Proper preparation will make the job smoother and help prevent potential issues. Here's what you'll need:

• New timing chain cover gasket set
• RTV silicone sealant
• Gasket scraper or razor blade
• Clean rags and solvent
• Socket set and ratchet
• Torque wrench
• Flat-head screwdrivers
• Pry bar (small)
• Hammer and punch (for aligning dowel pins)
• Timing cover alignment tool (if available)

It's important to clean all mating surfaces thoroughly before beginning the installation. Use a gasket scraper or razor blade to remove any old gasket material or sealant from both the engine block and the timing cover. Clean the surfaces with solvent and allow them to dry completely.

Inspect the new gasket set to ensure you have all the necessary components, including the main timing cover gasket, front oil seal, and any required rubber end seals. If your engine uses a two-piece oil pan design, you may need to replace the upper oil pan gasket as well.

Before removing the old timing cover, it's a good idea to mark the position of the oil pan in relation to the block. This will help you realign everything correctly during reassembly. You may also want to loosen the front oil pan bolts slightly to allow for some movement, but be careful not to disturb the oil pan gasket too much.

Removing the Old Timing Cover

Start by disconnecting the negative battery cable to prevent any electrical shorts. Remove any accessories blocking access to the timing cover, such as the water pump, harmonic balancer, and front engine mounts if necessary. Drain the cooling system if you're removing the water pump.

Carefully remove the bolts securing the timing cover to the engine block. There may be different length bolts, so keep track of their locations. Gently pry the cover away from the block, being careful not to damage the oil pan gasket. If the cover is stuck, use a rubber mallet to tap it loose, working around the edges.

Once the cover is free, clean the front of the engine thoroughly. Inspect the timing chain and gears for any signs of wear or damage. This is a good opportunity to replace these components if needed.

Installing the New Timing Cover

With the old cover removed and all surfaces cleaned, you're ready to install the new timing cover. Here's the step-by-step process:

1. Apply a thin bead of RTV silicone to the lower corners of the timing cover where it meets the oil pan. Don't use too much, as excess sealant can break off and clog oil passages.

2. Carefully place the new gasket onto the timing cover. Some gaskets may have adhesive to hold them in place. If not, you can use a small amount of sealant to tack it down.

3. Trim the lower corners of the timing cover gasket at a 45-degree angle. This will help it slide into place without bunching up against the oil pan.

4. Install the new front oil seal into the timing cover. Make sure it's seated properly and evenly.

5. Align the timing cover with the dowel pins on the engine block. You may need to use a hammer and punch to gently tap the cover into place.

6. Once aligned, start threading in the bolts by hand. Do not fully tighten them yet.

7. Use a pry bar or large flathead screwdriver to slightly lift the front of the oil pan. This will create a small gap to help the timing cover slip into place.

8. Carefully work the lower edge of the timing cover behind the oil pan lip. This may take some patience and maneuvering.

9. Once the cover is seated properly, begin tightening the bolts in a cross-pattern sequence. Start from the center and work your way outward.

10. Torque the bolts to the manufacturer's specifications using a torque wrench. This is typically around 15-20 ft-lbs for most engines, but always check your specific model.

11. After torquing, recheck all bolts to ensure they're properly tightened.

12. Apply a small bead of RTV silicone along the seam where the timing cover meets the oil pan. Smooth it out with your finger for a clean finish.

Final Steps and Precautions

After installing the timing cover, there are a few final steps to complete:

• Reinstall any components you removed, such as the water pump, harmonic balancer, and engine mounts.
• Refill the cooling system if you drained it.
• Double-check all connections and ensure everything is tight.
• Clean up any excess sealant that may have squeezed out during installation.

It's crucial to allow the RTV silicone to cure for the recommended time before starting the engine. This is typically 24 hours, but check the product instructions for specific curing times. Once cured, start the engine and check for any leaks around the timing cover and oil pan.

If you notice any oil seepage after running the engine, don't panic immediately. Sometimes it takes a few heat cycles for everything to fully seat and seal. However, if you see significant leaks, you may need to remove the cover and try again, ensuring proper alignment and sealing.

Remember, while this method can save time, it's not always the best option for every situation. If you're uncomfortable with the process or encounter significant difficulties, it may be better to remove the oil pan and install the timing cover the traditional way.

FAQs About Installing Timing Chain Cover With Oil Pan On

• Can I reuse the old timing cover gasket?
  It's not recommended. Always use a new gasket set for the best seal and to prevent leaks.
• How long should I wait before starting the engine after installation?
  Allow the RTV silicone to cure for at least 24 hours before starting the engine.
• What if I can't get the timing cover to seat properly?
  If you're having difficulty, it may be necessary to remove the oil pan for proper installation.
• Is it normal to see a small amount of oil seepage after installation?
  A small amount of seepage may occur initially but should stop after a few heat cycles.
• Do I need to replace the timing chain when installing a new cover?
  It's not always necessary, but it's a good opportunity to inspect and replace if worn.