Removal and Installation of Timing Case Cover

REMOVAL
- Lift hood to a 90° angle and engage left hand locking lever.
- Disconnect battery ground cable.
- Drain cooling system and engine oil.
- Remove air cleaner assembly.
- Disconnect accelerator linkage.
- Remove radiator. Radiator
- Remove the drive belt. Drive Belt
- Remove the drive belt tensioner. Drive Belt Tensioner
- Remove the water pump. Water Pump
- Remove vibration damper. Harmonic Balancer - Crankshaft Pulley
- Remove ignition distributor.
- Remove oil pan. Service and Repair





- On models equipped with self leveling suspension, unbolt pressure oil pump, place to the side with lines connected (arrows).

- Remove cylinder head cover. Valve Cover





- Remove hexagon socket bolts (arrows) in the chain box with a stud wrench.
^ Tightening torque 25 Nm (18.5 ft lbs) (reference value).





- Remove V-bracket (145) for power steering pump and A/C compressor (arrows).
^ Tightening torque 25 Nm (18.5 ft lbs)





- Unbolt power steering pump (arrows) and place to the side with the lines connected.
^ Tightening torque: 25 Nm (18.5 ft lbs)





- Unbolt A/C compressor (425) at the supporting bracket and place to the side with lines connected. Unbolt bracket (b).
^ Tightening torque bolts (149b): 25 Nm (18.5 ft lbs)





- Unplug connector (327) at the alternator.





- Remove alternator bolts (49 and 51), remove alternator.
^ Tightening torque 30 Nm (22 ft lbs).
- Unbolt alternator mounting bracket.
^ Tightening torque 25 Nm (18.5 ft lbs).
- Remove vibration damper and crankshaft pulley.





- Unbolt TDC pulse generator cable (1) at the holder (2).





- Unbolt bracket (8) for oil pump strainer basket (arrows).





- Remove remaining bolts (arrows) for timing case cover.
^ Tightening torque 25 Nm (18.5 ft lbs)
- Remove timing case cover.

Caution! Do not damage cylinder head gasket. Replace cylinder head gasket if damaged.

INSTALLATION NOTES
- Install in reverse order of removal.
- Clean mating faces.
- Coat mating face of timing case cover with the sealant, Part No. 001 989 25 20.
- Carefully install timing case cover, paying attention to the cylinder head gasket, and bolt tight.
^ Tightening torque 25 Nm (18.5 ft lbs).
^ Note the bolt lengths.





- If the radial seal has been removed, insert new radial seal with the sleeve 102 589 00 14 00.
- Install spacer ring (01) 102 589 01 14 00 for the timing case cover with double roller chain.

NOTE: If the timing case cover has been replaced, the TDC pulse generator holder must be adjusted.

- The remaining parts are installed in the reverse order.
- Run engine and check for leaks.

TIGHTENING TORQUES:
Timing case cover bolts: 25 Nm (18.5 ft lbs)
Alternator mounting bracket bolts: 25 Nm (18.5 ft lbs).
Alternator bolts (49 and 51): 30 Nm (22 ft lbs).
A/C compressor bolts (149b): 25 Nm (18.5 ft lbs)
Power steering pump bolts: 25 Nm (18.5 ft lbs)
V-bracket for power steering pump and A/C compressor: 25 Nm (18.5 ft lbs)