Timing Chain Cover Removal and Installation

TIMING CHAIN COVER
REMOVAL





1. Remove the engine from the vehicle.
2. Separate the engine from the transmission.





3. Remove the clutch cover (1) and the clutch (2) if equipped.
4. Mount the engine on a stand.





5. Remove the accessory drive belt.





6. Remove the lower oil pan. Remove the bolts (1) and remove the upper oil pan.
7. Remove the power steering pump.
8. Remove the idler pulley.





9. Remove the bolt (1) and remove the vibration damper (2).
10. Remove the generator.





11. Rotate the crankshaft to 40° ATDC.





12. Remove the starter.
13. Using Special Tool 9102 (1) Flywheel Locking Tool, lock the flywheel by inserting the tool into the starter opening.





14. Remove the cylinder head bolts (1) and remove the cylinder heads.
15. Remove the timing chain tensioner.





16. Remove the timing chain cover bolts as shown. Remove the timing chain cover.

INSTALLATION

Note: Ensure all sealing surfaces have been cleaned and prepared properly for effective repair. Multi-Layer Steel (MLS) gaskets require a scratch free sealing surface.





1. Install the cylinder heads, and install the bolts (1).





2. Align the basic valve timing to 40 deg. ATDC.





Note: Apply sealer ONLY to the area marked (1) as shown. If porous points are visible at the cylinder heads or at the rear of the engine near the sealing surface of the cylinder head gasket, apply sealant at these points. The sealant must be applied only as a 2.0 mm ± 0.5 mm bead, assembled within 10 minutes, and not be flattened or spread.

3. Apply a 1.5 to 2.0 mm bead of Loctite 5203 or equivalent sealer to the area marked (1) as shown.
4. Position the timing chain cover on the front of the engine.





Note: Ensure that the bolts indicated by the arrows are installed with thread sealer prior to assembly.

5. Install the timing chain cover bolts and tighten to 20 Nm (15 ft. lbs.).





6. Install the timing chain tensioner (1), tighten to 80 Nm (59 ft. lbs.).





7. Remove Special Tool 9102 Flywheel Locking Tool (1) from the engine.
8. Install the starter.
9. Install a new front crankshaft radial oil seal.
10. Install the generator.





11. Install the vibration damper.
12. Install the idler pulley.





13. Install the power steering pump, return hose (1), and pressure hose (2).





14. Install the upper and lower (1) oil pan.





15. Install the accessory drive belt.





16. Remove the engine from the stand.
17. Install the clutch if equipped.
18. Install the transmission on the engine.
19. Install the engine in the vehicle.