Timing Cover: Service and Repair
Engine Front Cover Replacement
Special Tools
* EN 46109 - Guide Pin Set
* EN-48383 - Camshaft Retaining Tools
* EN-48589 - Crankshaft Rotational Socket
* EN-46104 - Water Pump Pulley Holding Tool
Removal Procedure
1. Remove the frame from the body with the engine and transmission. Refer to Engine Replacement Engine Replacement.
Follow steps 1-40 in the Engine Replacement Removal.
2. Remove the intake manifold. Refer to Intake Manifold Removal Intake Manifold Removal.
Note: It is not necessary to remove the lines.
3. Remove the power steering reservoir bracket bolts and reposition.
Note: It is not necessary to remove the lines.
4. Remove the power steering pump bracket bolts and reposition.
5. Remove the left and right camshaft covers. Refer to Camshaft Cover Removal - Left Side (LLT) Camshaft Cover Removal - Left Side (LLT) and Camshaft Cover Removal - Right Side Camshaft Cover Removal - Right Side.
6. Remove the engine mount bracket bolts and bracket.
7. Remove the water outlet housing assembly. Refer to Water Outlet Removal Water Outlet Removal.
8. Remove the drive belt and drive belt tensioner. Refer to Drive Belt Tensioner Removal Drive Belt Tensioner Removal.
9. Remove the water pump pulley using EN-46104 - Holding Tooland if necessary remove the water pump. Refer to Water Pump Removal Water Pump Removal.
10. Remove the oil filter.
11. Remove the starter heat shield.
12. Remove the starter electrical connections, starter bolts and starter.
13. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal Crankshaft Balancer Removal.
14. Remove the drive belt idler bolt and idler. Refer to Drive Belt Idler Pulley Removal Drive Belt Idler Pulley Removal
15. Remove the generator.
16. Remove camshaft position sensors (2) from the front cover.
17. Remove the camshaft position actuators from the front cover.
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.
18. Remove the engine front cover. Engine Front Cover Removal Engine Front Cover Removal.
Installation Procedure
1. Install front cover. Refer to Engine Front Cover Installation Engine Front Cover Installation.
2. Install the camshaft position actuators to the front cover.
3. Install the camshaft position sensors (2) to the front cover.
4. Install the generator.
5. Install the drive belt idler bolt and idler. Refer to Drive Belt Idler Pulley Installation Drive Belt Idler Pulley Installation
6. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation Crankshaft Balancer Installation.
7. Install the starter, starter bolts and starter electrical connections.
8. Install the starter heat shield.
9. Install the oil filter.
10. If removed, install the water pump and the water pump pulley using EN-46104 - Holding Tool. Refer to Water Pump Installation Water Pump Installation.
11. Install the drive belt tensioner and drive belt. Refer to Drive Belt Tensioner Installation Drive Belt Tensioner Installation.
12. Install the water outlet housing assembly. Refer to Water Outlet Installation Water Outlet Installation.
13. Install the engine mount bracket and bracket bolts.
14. Remove the left and right camshaft covers. Refer to Camshaft Cover Installation - Left Side Camshaft Cover Installation - Left Side and Camshaft Cover Installation - Right Side Camshaft Cover Installation - Right Side.
Caution: Refer to Fastener Caution Fastener Caution.
15. Reposition the power steering pump and install the bracket bolts. Tighten the bolts to 50 Nm (37 lb ft).
16. Install the power steering reservoir and install the bracket bolts. Tighten the bolts to 9 Nm (80 lb in).
17. Remove the intake manifold. Refer to Intake Manifold Installation Intake Manifold Installation.
18. Install the frame with the engine and transmission. Refer to Engine Replacement Engine Replacement.
Follow steps 16-49 in Engine Replacement Installation.