Timing Cover: Service and Repair
Engine Front CoverService Repair No - 12.65.01
Special Service Tools
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. Remove the coolant manifold.
4. Remove the cooling fan drive belt tensioner.
^ Remove the bolt.
NOTE: Restrain the pulley to aid the removal of the bolts.
5. Remove the cooling fan pulley.
^ Remove the 3 bolts.
6. Remove the cooling fan drive hub bearing.
^ Remove the 5 bolts.
7. Release the accessory drive belt.
^ Rotate the accessory drive belt tensioner counter-clockwise, using a 3/8" drive wrench.
NOTE: Restrain the pulley to aid the removal of the bolts.
8. Remove the coolant pump pulley.
^ Remove the 3 bolts.
9. Remove the accessory drive belt tensioner.
^ Remove the bolt.
10. NOTE: Note the fitted position.
Remove the accessory drive belt.
11. Remove the accessory drive belt idler pulley.
^ Remove the bolt.
^ Repeat the above procedure for the remaining idler pulley.
12. Remove the oil level indicator and tube.
13. Remove the LH front wheel.
CAUTION: Immediately cap all refrigerant lines to prevent ingress of dirt and moisture.
14. Disconnect the refrigerant lines from the A/C compressor.
^ Remove the 2 bolts.
^ Remove and discard the 2 O-ring seals.
15. Disconnect the A/C clutch electrical connector.
NOTE: 1 A/C compressor bolt will remain captive until the mounting bracket is removed.
16. Release the A/C compressor.
^ Remove the 3 bolts.
17. Remove the A/C compressor mounting bracket.
^ Remove the 2 bolts.
18. Remove the A/C compressor.
19. Remove the exhaust manifold heat shield.
^ Remove the 2 screws.
20. Disconnect the battery positive cable.
^ Release the cover.
^ Remove the nut.
21. Remove the generator.
^ Remove the 3 bolts.
^ Disconnect the electrical connector.
22. Release the generator mounting bracket.
^ Loosen the lower rear bolt.
^ Remove the 3 remaining bolts.
CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft.
23. Using the special tools, retain the crankshaft pulley.
NOTE: The crankshaft pulley retaining bolt will be very tight.
24. Remove the crankshaft pulley retaining bolt.
^ Discard the bolt.
^ Remove the special tools.
NOTE: The crankshaft pulley will be very tight.
25. Using the special tools, remove the crankshaft pulley.
^ Collect the locking ring.
^ Remove the special tools.
26. Using the special tool, remove and discard the crankshaft front seal.
27. Check the crankshaft damper pulley and locking ring for damage.
28. Remove the RH valve cover.
29. Remove the LH valve cover.
30. Release the engine wiring harness.
^ Release the 2 clips.
^ Remove the bolt.
31. Remove the engine front cover.
^ 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.
^ Install a new gasket.
2. Evenly and progressively tighten the bolts in the sequence shown to 12 Nm (9 ft. lbs.).
3. Attach the engine wiring harness.
^ Secure the clips.
^ Tighten the bolt to 10 Nm (7 ft. lbs.).
4. Install the LH valve cover.
5. Install the RH valve cover.
6. Using the special tools, install the crankshaft front seal.
^ Lubricate the seal with clean engine oil.
^ Use the discarded crankshaft bolt with the special tool.
^ Remove the special tools.
7. Install the crankshaft pulley.
^ Lubricate the seal with clean engine oil.
8. 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.
9. 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.
10. Using the special tools, retain the crankshaft pulley.
^ Tighten the crankshaft pulley bolt to 380 Nm (280 ft. lbs.).
^ Remove the special tools.
11. Secure the generator mounting bracket.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
12. Install the generator.
^ Tighten the 3 bolts to 48 Nm (35 ft. lbs.).
^ Connect the electrical connector.
13. Connect the battery positive cable.
^ Tighten the nut to 10 Nm (7 ft. lbs.).
^ Secure the cover.
14. Install the exhaust manifold heat shield.
^ Tighten the screws.
15. Install the accessory drive belt idler pulleys.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
16. Position the A/C compressor to the engine.
^ If a new compressor is being installed, the required amount of refrigerant oil must be drained from it.
17. Install the A/C compressor mounting bracket.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
18. Secure the A/C compressor.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
19. Connect the A/C clutch electrical connector.
CAUTION: Lubricate the new seals with clean refrigerant oil.
20. Connect the refrigerant lines.
^ Clean the component mating faces.
^ Install the new O-ring seals.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
21. Install the front wheel.
^ Tighten the wheel nuts to 140 Nm (103 ft. lbs.).
22. Install the oil level indicator and tube.
23. Install the coolant pump pulley.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
24. Install the accessory drive belt.
25. Install the accessory drive belt tensioner.
^ Tighten the bolt to 40 Nm (30 ft. lbs.).
26. Install the cooling fan drive hub bearing.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
27. Install the cooling fan pulley.
^ Tighten the bolts evenly to 25 Nm (18 ft. lbs.).
28. Secure the accessory drive belt.
29. Install the cooling fan drive belt tensioner.
^ Tighten the bolt to 40 Nm (30 ft. lbs.).
30. Install the coolant manifold.
31. Connect the battery ground cable.
32. Refill and bleed the cooling system.