Timing Cover: Service and Repair

TIMING CHAIN COVER

REMOVAL
1. Disconnect the negative battery cable.
2. Drain the cooling system
3. Remove the engine cover
4. Remove the radiator fan
5. Remove the accessory drive belt.
6. Remove the idler pulley.
7. Remove accessory drive belt tensioner





8. Remove the vibration damper.
9. Disconnect lower radiator and heater hoses from the water pump.
10. Remove the power steering pump.
11. Remove the AIR pump.
12. Remove the cylinder head covers.
13. Remove the front cylinder head to timing chain cover retaining bolts.
14. Remove the generator
15. Raise and support vehicle.
16. Remove the lower oil pan
17. Remove the upper oil pan
18. Remove the starter.





19. Rotate the crankshaft to 40° ATDC.





20. Using Special Tool 9102 (1) Flywheel Locking Tool, lock the flywheel by inserting the tool into the starter opening.
21. Remove the timing chain tensioner.
22. Remove the timing chain cover bolts and cover.

INSTALLATION





1. Be sure valve timing is still locked at 40° 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.

NOTE:

2. Apply a 1.5 to 2.0 mm bead of Loctite 5900 or equivalent sealer to the area marked (1) as shown.
3. 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.

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





5. Install the timing chain tensioner (1). Tighten to 80 Nm (59 ft. lbs.)





6. Remove Special Tool 9102 Flywheel Locking Tool (1) from the engine.
7. Install the starter
8. Install the upper oil pan
9. Install the lower oil pan
10. Install the generator.

NOTE: Apply a thin coat of lubricant to head bolt threads before installing.

11. Install the front cylinder head to timing chain cover bolts. Tighten bolts to 20 Nm (7-15 ft. lbs.).
12. Install the cylinder head covers
13. Install the AIR pump.





14. Install the power steering pump, return hose (1), and pressure hose (2).
15. Install the lower radiator and heater hoses to the water pump.
16. Install the vibration damper.
17. Install the idler pulley.
18. Install the accessory drive belt tensioner.
19. Install the accessory drive belt.
20. Install the radiator fan
21. Install the engine cover
22. Refill all engine fluids to specifications.
23. Connect the negative battery cable.