Timing Cover: Service and Repair

ENGINE FRONT COVER REPLACEMENT

Tools Required
^ EN 46109 Engine Front Cover Installation Guide Pins

Removal Procedure
1. Remove the engine cover. Service and Repair

2. Remove the upper intake manifold with the lower intake manifold. Service and Repair

3. Remove the camshaft covers. Service and Repair

4. Drain the engine coolant. Service and Repair

5. Disconnect the purge vent hose from the water outlet.

6. Remove the water outlet with the radiator hose and reposition aside. Service and Repair

7. Remove the accessory drive belts. Service and Repair

8. Remove the A/C compressor and power steering belt tensioner. Service and Repair

9. Remove the generator bracket with the generator and the belt tensioner. Service and Repair

Important: Do not disconnect the power steering pipes or drain the power steering fluid.

10. Remove the power steering fluid reservoir and reposition the power steering fluid reservoir in order to provide access. Service and Repair

11. Remove the power steering pump pulley. Service and Repair

Important: Do not disconnect the power steering pipes/hoses.

12. Remove the power steering pump upper front bolt and loosen the remaining two bolts. Service and Repair

13. Remove the crankshaft balancer. 10. Crankshaft Balancer Removal

14. Remove the camshaft position sensors. Service and Repair

15. Remove the camshaft position actuator solenoid valves from the front cover. Service and Repair

Important: There are a total of 22 M8 bolts that must be removed and 3 optional M12 bolts that may need to be removed before the front cover will separate from the engine block.






16. Remove the engine front cover with the water pump. 15. Engine Front Cover Removal

17. Disassemble the engine front cover as necessary. 75. Engine Front Cover Disassemble

Important: Do NOT use sharp and/or metal gasket scrapers in order to clean the sealing surfaces.

18. Carefully clean the engine front cover sealing surfaces. 76. Engine Front Cover Cleaning and Inspection

Important: Insert a piece of cardboard between the oil pan front and the oil pump in order to prevent any contaminants from falling into the oil pan.

19. Use compressed air in order to remove any engine coolant from the engine cooling passages and from the top of the oil pan scraper (windage tray).

Installation Procedure
1. Assemble the engine front cover as necessary. 77. Engine Front Cover Assemble






2. Install the engine front cover. 123. Engine Front Cover Installation

3. Install the camshaft position actuator solenoid valves to the front cover. Service and Repair

4. Install the camshaft position sensors. Service and Repair

5. Install the crankshaft balancer. 129. Crankshaft Balancer Installation

6. Install the power steering pump.Service and Repair

7. Install the power steering pump pulley. Service and Repair

8. Install the power steering fluid reservoir. Service and Repair

9. Install the generator bracket with the generator and the belt tensioner. Service and Repair

10. Install the A/C compressor and power steering belt tensioner. Service and Repair

11. Install the accessory drive belts. Service and Repair

12. Install the water outlet. Service and Repair

13. Install the purge vent hose to the water outlet.

14. Install the camshaft covers. Service and Repair

15. Install the upper intake manifold with the lower intake manifold. Service and Repair

16. Install the engine cover. Service and Repair

17. Fill the cooling system. Service and Repair