Timing Cover: Service and Repair
Engine Front Cover Replacement
Special Tools
EN 46109 Engine Front Cover Installation Guide Pins
Removal Procedure
1. Remove the engine covers. Service and Repair
2. Remove the upper intake manifold with the lower intake manifold. Service and Repair
3. Remove the camshaft covers. Service and Repair
4. Drain the engine coolant. Service and Repair
5. Remove the radiator outlet hose. Service and Repair
6. Compress the coolant bleed hose retaining clamp (4) at the outlet housing (1) end and slide 50 mm (2 in) along the coolant bleed hose (3).
7. Remove the coolant bleed hose (3) from the outlet housing (1).
Note: Twist and pull the coolant recovery hose (2) to remove from the outlet housing (1).
8. Disconnect the coolant recovery hose (2) from the outlet housing (1).
Note: Plug or cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.
9. Plug or cap the cooling system hoses and inlets.
10. Remove the water outlet housing. Service and Repair
11. Remove the drive belt. Service and Repair
12. Remove the drive belt tensioner. Service and Repair
13. Remove the alternator bracket with the alternator. Service and Repair
Note: DO NOT disconnect the power steering pipes or drain the power steering fluid.
Note: The locking tang on the power steering reservoir bracket (2) must be released before removing the power steering reservoir (1). Release the locking tang on the power steering reservoir bracket (2) with a suitable tool.
14. Separate power steering fluid reservoir (1) from the power steering fluid reservoir bracket (2).
15. Reposition and secure the power steering fluid reservoir away from the power steering fluid reservoir (1) bracket (2).
Note: DO NOT disconnect the power steering pipes/hoses.
Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.
Note: Make sure all the bolt holes are thoroughly cleaned and all micro-encapsulated thread sealant is removed.
16. Remove the power steering pump to power steering bracket retaining bolts (3).
* Discard the bolts.
* Clean the bolt holes.
17. Remove the power steering pump (1) from the power steering bracket (2).
18. Secure and reposition the power steering pump (1) away from the power steering bracket (2).
Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.
Note: Make sure all the bolt holes are thoroughly cleaned and all micro-encapsulated thread sealant is removed.
19. Remove the power steering fluid reservoir bracket to engine front cover retaining bolts (5).
* Discard the bolts.
* Clean the bolt holes.
20. Remove the power steering fluid reservoir bracket (6).
Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.
Note: Make sure all the bolt holes are thoroughly cleaned and all micro-encapsulated thread sealant is removed.
21. Remove the power steering bracket to cylinder head retaining bolt (3).
* Discard the bolt.
* Clean the bolt hole.
Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.
Note: Make sure all the bolt holes are thoroughly cleaned and all micro-encapsulated thread sealant is removed.
22. Remove the power steering bracket to engine front cover retaining bolt (1).
* Discard the bolt.
* Clean the bolt hole.
Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.
Note: Make sure all the bolt holes are thoroughly cleaned and all micro-encapsulated thread sealant is removed.
23. Remove the power steering bracket to cylinder block retaining bolt (2).
* Discard the bolt.
* Clean the bolt hole.
24. Remove the power steering pump bracket (4).
25. Disconnect the A/C pressure transducer electrical connector (4).
26. Disconnect the A/C compressor electrical connector (5).
Note: DO NOT disconnect the A/C pipes (2) from the A/C compressor (6).
27. Remove the A/C compressor to A/C compressor/power steering pump mounting bracket retaining bolts (1).
28. Secure and reposition the A/C compressor (6) away from the A/C compressor mounting bracket (3).
29. Remove the compressor bracket mounting bolts (1).
30. Remove the compressor bracket (2).
31. Remove the crankshaft balancer. Service and Repair
32. Remove the camshaft position sensors. Service and Repair
33. Remove the camshaft position (CMP) actuator solenoids. Service and Repair
34. Remove the engine front cover with the water pump. 22. Engine Front Cover Removal
35. Disassemble the engine front cover as necessary. 77. Engine Front Cover Disassemble
Note: DO NOT use sharp and/or metal gasket scrapers in order to clean the sealing surfaces.
36. Carefully clean the engine front cover sealing surfaces. 78. Engine Front Cover Cleaning and Inspection
Note: Insert a piece of cardboard between the oil pan front and the oil pump in order to prevent any contaminants from falling into the oil pan.
37. Carefully clean the engine front cover sealing surfaces.
38. Use compressed air in order to remove any engine coolant from the engine cooling passages and from the top of the oil pan scraper (windage tray).
Installation Procedure
1. Assemble the engine front cover as necessary. 79. Engine Front Cover Assemble
2. Use the EN 46109 to install the engine front cover. 120. Engine Front Cover Installation
3. Install the camshaft position (CMP) actuator solenoids. Service and Repair
4. Install the camshaft position sensors. Service and Repair
5. Install the crankshaft balancer. Service and Repair
6. install the compressor bracket (2).
7. Install the compressor bracket mounting bolts (1).
Note: Make sure the A/C pipes (2) are not twisted or kinked upon compressor installation.
8. Install the A/C compressor (6) with the A/C pipes (2) to the A/C compressor mounting bracket (3).
Caution: Refer to Fastener Caution (Fastener Caution).
9. Install the compressor to the compressor mounting bracket retaining bolts (1) and tighten to 22 Nm (16 lb ft)
10. Connect the A/C pressure transducer electrical connector (4).
11. Connect the A/C compressor electrical connector (5).
12. Install the power steering pump bracket (4).
13. Install a NEW power steering bracket to the cylinder head retaining bolt (3) and tighten to 58 Nm (43 lb ft).
14. Install a NEW power steering bracket to the engine front cover retaining bolts (1) and tighten to 58 Nm (43 lb ft).
15. Install a NEW power steering bracket to the cylinder block retaining bolt (2) and tighten to 58 Nm (43 lb ft).
16. Install the power steering fluid reservoir bracket (6).
17. Install the NEW power steering fluid reservoir bracket to the engine front cover retaining bolts (5) and tighten to 9 Nm (80 lb ft).
18. Install the power steering pump (2) to the power steering pump bracket (1).
19. Install the NEW power steering pump to the power steering pump bracket retaining bolts (3) and tighten to 27 Nm (22 lb ft).
Note: Make sure the power steering reservoir (1) and the locking tang on the power steering reservoir bracket (2) are engaged to avoid an induced rattle condition.
20. Install the power steering fluid reservoir (1) to the power steering fluid reservoir bracket (2).
21. Install the alternator bracket with the alternator. Service and Repair
22. Install the belt tensioner. Service and Repair
23. Install the drive belt. Service and Repair
24. Install the water outlet housing. Service and Repair
25. Remove the plug or cap at the cooling system hoses and inlets.
26. Install the coolant bleed hose (3) to the outlet housing (1).
27. Compress the coolant bleed hose retaining clamp (4) and position back to its original location on the coolant bleed hose (3).
28. Connect the coolant recovery hose (2) from the outlet housing (1).
29. Install the radiator outlet hose. Service and Repair
30. Install the camshaft covers. Service and Repair
31. Install the upper intake manifold with the lower intake manifold. Service and Repair
32. Install the engine covers. Service and Repair
33. Fill the cooling system. Service and Repair
34. Change the engine oil. Service and Repair