Contents: Removal ↡ Installation ↡
Removal
Note: This operation may require a hoist. The appropriate sealant will be required during installation. It is recommended to replace the front crankshaft oil seal.
1. Disconnect the negative battery terminal.
2. Raise the engine hood as far as it will go, as described in chapter 11.
3. Remove the engine crankcase guard.
4. Remove the radiator and fan with drive as described in chapter 3.
5. Remove the pulley/damper as described in paragraph 5.
6. Remove the accessory drive belt tensioner in the following order.
- a) Remove the plastic plug, unscrew the bolt and remove the auxiliary drive belt idler pulley.
- b) Loosen the bolt and remove the fan drive pulley.
- c) Loosen the bolt and remove the tensioner damper stand, noting the location of the gaskets and/or brackets.
- d) Using pliers, separate the tensioner spring, remembering its position to correctly install the spring during assembly.
- d) If necessary, remove the plastic cover, unscrew and remove the tensioner mounting bolt and remove the spacer sleeve.
- e) Remove the tensioner, remove the gasket.
7. Remove the brake booster pump as described in chapter 9.
8. Remove the power steering/adjustable suspension pump as described in chapter 10.
9. If necessary, remove the adjustable suspension hydraulic pump from the front of the cylinder head as described in chapter 10.
10. Remove the generator as described in chapter 5.
11. Drain the engine oil as described in chapter 1B.
12. Remove the camshaft cover as described in paragraph 4.
13. On air-conditioned models, place a piece of cardboard or some other shield in front of the condenser to protect it from damage during subsequent operations.
14. Remove the two bolts from the front of the fuel filter/thermostat assembly (see fig. 6.14).
15. Unscrew the engine oil dipstick tube from the cylinder head.
16. Loosen the bolts and remove the bracket supporting the generator, remembering the location of the bolts.
17. If equipped, mark the position of the crankshaft position sensor bracket on the camshaft timing chain cover and remove the bracket bolts.
18. If present, unscrew the fixing bolts and remove the engine vibration limiter, in accordance with paragraph 16.
19. If necessary, remove the two bolts and disconnect the lower end of the engine mount shock absorber on the left side from the cross member.
20. Place the hoist slings under the front engine mount.
21. While under the vehicle, remove the two lower engine mounting bolts (one on each side) (see fig. 6.21)
22. Using a lift, raise the engine to gain access to the oil pan to timing chain cover bolts.
23. Loosen and remove the oil pan mounting bolts to the camshaft drive chain cover, loosen the remaining oil pan mounting bolts.
24. Lower the engine so that it rests on the supports.
25. While holding the nuts, remove the three bolts securing the high-pressure fuel pump to the camshaft drive chain cover (see fig. 6.25).
26. Working through the hole on top of the cylinder head, unscrew the two bolts securing the cylinder head to the camshaft drive chain cover (see fig. 6.26)
Fig. 6.26 Unscrew the two bolts (shown by arrows) fastening the cylinder head to the camshaft drive chain cover
27. Gradually unscrew the remaining chain cover mounting bolts, remembering the location of each of them. (see fig. 6.27)
Fig. 6.27 Unscrew the remaining cover mounting bolts (shown by arrows)
28. Gently pull the cover forward on the cylinder block. If the cover is difficult to remove, tap the edges lightly with a hammer with a protected striker - do not use a lever inserted between the cover and the cylinder block for this purpose.
Caution: Be careful not to damage the cylinder head and oil pan gaskets when the timing chain cover is removed.
Installation
29. Begin installation by thoroughly cleaning the mating surfaces of the timing chain cover, cylinder block and cylinder head. Remove all traces of old sealant.
30. Carefully inspect the condition of the cylinder head gasket. If the gasket is damaged, the cylinder head must be removed to replace the gasket as described in paragraph 10.
31. Similarly, carefully inspect the condition of the oil pan gasket. If the gasket is found to be damaged during disassembly, the oil pan should be removed to replace the gasket as described in paragraph 11.
32. It is recommended to replace the crankshaft seal in the cover, following the following procedure.
- a) Pry up the old cuff using a screwdriver.
- b) Clean the seal seat in the crankshaft drive chain housing.
- c) Hammer the new seal (dry) into place using a suitable pipe or socket wrench until it rests against the ledge.
33. Wrap a piece of polyethylene or adhesive tape around the front end of the crankshaft flange to prevent damage to the seal when installing the cover.
34. Apply sealant to the surface of the camshaft timing chain cover adjacent to the cylinder block.
35. Lubricate the lip of the seal with engine oil, then install it in place. Be careful not to damage the lip of the seal, as well as the cylinder head and oil pan gaskets, when installing the cover.
36. Insert the bolts securing the chain cover to the cylinder block into place, then gradually tighten them to the required tightening torque.
37. Insert the cylinder head bolts into place on the chain cover and tighten them to the required tightening torque.
38. If you used it, remove the protective plastic from the front end of the crankshaft.
39. Install and tighten the high pressure fuel pump mounting bolts and nuts.
40. Use a hoist and winch to raise the engine to allow installation of the oil pan mounting bolts to the chain cover.
41. Install the oil pan to chain cover mounting bolts and gradually tighten them to the specified torque.
42. Lower the engine onto the supports, then install and tighten the lower engine mounting bolts.
43. If provided, install the engine shock absorber mounting bolts to the frame cross member.
44. If provided, install and secure the engine travel limiter as described in paragraph 16.
45. If necessary, install the crankshaft position sensor mounting bracket, making sure that the bracket is aligned with the marks made prior to removal.
46. Install the generator bracket, making sure the bolts are in place.
47. Install the oil dipstick mounting bolt to the cylinder head.
48. If required, install the fuel filter/thermostat assembly mounting bolts.
49. If present, remove the protective shield from the air conditioner condenser.
50. Install the camshaft cover in accordance with paragraph 4.
51. Install the generator in accordance with chapter 5.
52. If equipped, install the adjustable suspension hydraulic pump to the cylinder head in accordance with chapter 10.
53. Install the power steering/traction/adjustable suspension hydraulic pump as described in chapter 10.
54. Install the brake booster pump as described in chapter 9.
55. Install the accessory drive belt tensioner in the reverse order to that described in paragraph 5.
56. Install the pulley/damper and crankshaft hub in accordance with paragraph 5.
57. Install the fan drive unit and radiator as described in chapter 3.
58. Install the lower engine guard.
59. Fill the engine with the correct amount of engine oil of the required quality as described in chapter 1B.
60. Connect the negative battery terminal and lower the hood.