Timing Cover: Service and Repair
Engine Front CoverService Repair No - 12.65.01
Removal
1. Disconnect the battery ground cable.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
2. Raise and support the vehicle.
3. Drain the cooling system.
4. Remove the coolant manifold.
5. Remove the RH air cleaner assembly.
6. Remove the cooling fan drive pulley.
^ Remove the 3 bolts.
7. Remove the cooling fan drive hub bearing.
^ Remove the 5 bolts.
8. Remove the cooling fan belt tensioner.
^ Remove the bolt.
9. Release the accessory drive belt.
^ Rotate the accessory drive belt tensioner counter-clockwise, using a 3/8" drive wrench.
NOTE: Note the fitted position.
10. Remove the accessory drive belt.
11. Using the special tools, retain the crankshaft pulley.
CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft.
NOTE: The crankshaft pulley retaining bolt will be very tight.
12. Remove the crankshaft pulley retaining bolt.
^ Discard the bolt.
13. Remove the special tools.
14. Using the special tools, remove the crankshaft pulley.
^ Collect the locking ring.
15. Remove the special tools from the crankshaft pulley.
16. Using the special tool, remove the crankshaft front seal.
^ Remove the outer section of the seal.
^ Repeat the process to remove the inner section of seal.
17. Check the crankshaft damper pulley and locking ring for damage.
18. Remove the LH front wheel.
CAUTION: Always plug any open connections to prevent contamination.
19. Disconnect the low pressure line.
^ Release the clip.
^ Allow the fluid to drain into a container.
20. Disconnect the high pressure line.
^ Remove and discard both O-ring seals.
21. Remove the power steering pump.
^ Remove the 4 bolts.
22. Remove the accessory drive belt tensioner.
^ Remove the bolt.
23. Release the transmission cooler pipe clips.
24. Remove the power steering pump mounting bracket.
^ Remove the 3 bolts.
CAUTION: Always plug any open connections to prevent contamination.
25. Disconnect the refrigerant lines from the A/C compressor.
^ Remove the 2 bolts.
^ Remove and discard the O-ring seal.
26. Disconnect the A/C clutch electrical connector.
NOTE: 1 A/C compressor bolt will remain captive until the mounting bracket is removed.
27. Release the A/C compressor.
^ Fully loosen the upper front bolt.
^ Remove the remaining 2 bolts.
28. Remove the A/C compressor mounting bracket and the A/C compressor.
^ Remove the 2 bolts.
29. Remove the accessory drive belt idler pulley.
^ Remove the bolt.
30. Remove the coolant pump pulley.
^ Remove the 3 bolts.
31. Remove the battery positive cable.
^ Release the battery positive cable cover.
^ Remove the retaining nut.
^ Disconnect the generator electrical connectors.
32. Remove the generator.
^ Remove the 3 bolts.
33. Release the generator mounting bracket.
^ Loosen the lower rear bolt.
^ Remove the 3 remaining bolts.
34. Remove the RH valve cover.
35. Remove the LH valve cover.
36. Remove the engine front cover.
^ Release the engine wiring harness clips.
^ Remove the 24 bolts.
^ Remove and discard the gasket.
Installation
1. Install the engine front cover.
^ Clean the component mating faces.
^ Apply a bead of sealant 3 mm diameter, by 12 mm long, to the 8 places indicated.
2. Secure the engine front cover.
CAUTION: Tighten the bolts in the sequence shown.
^ Tighten the bolts to 12 Nm (9 ft. lbs.).
3. Install the LH valve cover.
4. Install the RH valve cover.
5. Secure the generator mounting bracket.
^ Clean the locating dowels.
^ Clean the component mating faces.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
6. Install the generator.
^ Install and tighten the generator upper fixing bolt, before the lower bolts.
^ Tighten the 3 bolts to 48 Nm (35 ft. lbs.).
7. Install the battery positive cable.
^ Connect the battery positive cable.
^ Tighten the nut to 10 Nm (7 ft. lbs.).
^ Connect the generator electrical connector.
8. Install the coolant pump pulley.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
9. Install the accessory drive belt idler pulley.
^ Tighten the bolt to 25 Nm (18 ft. lbs.).
10. Install the A/C compressor and the A/C compressor mounting bracket.
^ If a new compressor is being installed, the required amount of refrigerant oil must be drained from it.
11. Secure the A/C compressor mounting bracket.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
12. Secure the A/C compressor.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
13. Connect the A/C clutch electrical connector.
CAUTION: Lubricate the new seals with clean refrigerant oil.
14. Connect the refrigerant lines.
^ Clean the component mating faces.
^ Install the new O-ring seals.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
15. Secure the transmission cooler pipes into clips.
16. Install the power steering pump.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
17. Connect the high pressure line.
^ Clean the component mating faces.
^ Install the new O-ring seals.
^ Tighten the union to 25 Nm (18 ft. lbs.).
18. Connect the low pressure line.
^ Clean the component mating faces.
^ Secure with the clip.
19. Clean all the crankshaft pulley mating faces.
20. Using the special tools, install the crankshaft front seal.
^ Lubricate the seal with clean engine oil.
^ Use the discarded crankshaft bolt with the service tool.
21. Install the front wheel.
^ Tighten the wheel nuts to 140 Nm (103 ft. lbs.).
22. Install the crankshaft pulley.
^ Lubricate the seal with clean engine oil.
23. Install the crankshaft pulley locking ring.
CAUTION: The screw thread in the crankshaft pulley must be cleaned out before installing a new crankshaft pulley bolt.
24. Install, but do not tighten, the new crankshaft pulley bolt.
CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft.
25. Using the special tools, retain the crankshaft pulley.
^ Tighten the crankshaft pulley bolt to 380 Nm (280 ft. lbs.).
26. Remove the special tools.
27. Install the accessory drive belt.
28. Install the cooling fan belt tensioner.
^ Tighten the M10 bolt to 45 Nm (33 ft. lbs.).
29. Install the cooling fan drive hub bearing.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
30. Install the cooling fan drive pulley.
^ Tighten the bolts evenly to 25 Nm (18 ft. lbs.).
31. Install the RH air cleaner assembly.
32. Install the coolant manifold.
33. Refill and bleed the cooling system.