Timing Cover
TIMING CHAIN COVERREMOVAL
WARNING: DO NOT OPEN COOLING SYSTEM UNLESS TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN APPROVED CONTAINER ONLY. RISK OF INJURY TO SKIN AND EYES FROM SCALDING COOLANT. WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.
1. Disconnect negative battery cable.
NOTE: Rotate engine on crankshaft. DO NOT crank the engine at the bolt of the camshaft sprocket.
NOTE: DO NOT crank engine back.
2. Position piston of cylinder 1 to ignition TDC. Markings on the camshaft bearing cap must be aligned.
3. Drain coolant.
4. Install retaining lock for crankshaft/starter ring gear.
5. Drain engine oil.
6. Remove the oil filter to allow the oil to flow off into the oil pan.
7. Remove the radiator assembly.
8. Remove engine cover.
9. Remove front cover at cylinder head.
10. Remove accessory drive belt.
11. Remove the high pressure fuel pump.
12. Remove water pump.
13. Remove accessory drive belt pulley and vibration damper.
14. Remove the power steering pump.
NOTE: NO NOT open the air conditioning system.
15. Unplug AC compressor electrical connector and unbolt AC compressor. Relocate in lower engine compartment with out opening the system.
16. Remove the generator with wiring attached and relocate somewhere in the engine compartment.
17. Install engine support fixture.
18. Remove the oil pan.
19. Detach the coolant hose to oil-water heat exchanger at crankcase (Fig. 71).
20. Remove the cylinder head to timing cover bolts (Fig. 71).
21. Remove the timing cover bolts and cover (Fig. 71).
22. Remove remaining ancillary components attached to the timing case cover (Fig. 71).
NOTE: Inspect condition of hoses and clamps, replace as necessary.
23. Remove timing chain tensioner
24. Remove timing case cover (Fig. 71).
INSTALLATION
CAUTION: Care must be taken to closely inspect the gasket area around the time case cover to cylinder head gasket coolant port. If damage is found, replace the cylinder head gasket. Failure to do so may result in engine damage.
NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure that no grease or oil is present during assembly.
1. Inspect cylinder head gasket and oil pan gasket. If damaged, replace.
2. Replace the front crankshaft seal.
3. Install ancillary components to timing case cover.
4. Apply sealant to the marked surfaces with a bead thickness of 1.5 ± 0.5 mm (Fig. 72).
NOTE: Install timing cover within 10 minutes after applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the crankcase. Sealant applied at these points is entrained by the oil flow and blocks the oil supply passages.
5. Position and install timing case cover. Tighten bolts to 20 Nm (177 inch lbs.) (Fig. 71).
6. Install the M8 bolts of cylinder head on timing case cover. Tighten bolts to 20 Nm (177 inch lbs.) (Fig. 71).
7. Install timing chain tensioner with new seal.
8. Position and install the oil pan. Tighten M6 bolts to 9 Nm (80 inch lbs.) and M8 bolts to 20 Nm (177 inch lbs.).
9. Install belt /pulley vibration damper. Tighten M8.8 bolt in two stages, 200 Nm (147 ft. lbs.) then 90°, M10.9 bolt 325 Nm (240 ft. lbs.) then 90°.
10. Remove the engine support fixture.
11. Install generator.
12. Install the air conditioning compressor.
13. Install the power steering pump.
14. Install water pump.
15. Connect coolant hose to oil-water heat exchanger.
16. Install high pressure fuel pump.
17. Apply sealant to lower portion of, and install, front cover to cylinder block. Tighten bolts to 20 Nm (177 inch lbs.).
18. Remove retaining lock for crankshaft/starter ring gear.
19. Tighten the oil drain plug to 30 Nm (265 inch lbs.).
20. Install a new oil filter. tighten screw cap for filter to 25 Nm (221 inch lbs.).
21. Install the accessory drive belt.
22. Install the radiator assembly.
23. Install air intake hose.
24. Fill coolant to the proper level, with the proper coolant.
25. Fill the crankcase with the correct oil, to the proper level. Refer to owners manual for specifications.
26. Connect the negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.
CAUTION: DO NOT pressure test cooling system until the engine reaches operating temperature.
27. Start engine and inspect for leaks. care must be taken to observe the fuel system warning.