Contents: Removal ↡ Installation ↡
Removal
Location of coolant supply pipe and engine lifting eye mounting bolt
1 – pipe fastening bolt; 2 – pipe for supplying coolant; 3 – nut; 4 – bolt
Power Steering Pump Bracket Fasteners
1 – bracket; 2 – central bolt; 3 – bracket mounting bolts
Location of bolts (1) for fastening bracket (2) of radiator fan pulley
Location of oil pan to lower timing chain cover bolts
Location of remaining lower drive chain cover mounting bolts
1. Remove the ground cable from the battery.
2. Open the hood and place it in a vertical position.
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3. If present, remove the engine splash shield.
4. Remove the air filter.
5. Remove the radiator and fan impeller.
6. Unscrew the bolt securing the air intake pipe to the body panel and remove the pipe.
7. Remove the auxiliary drive belt.
8. Remove the bolts and pulleys of the auxiliary drive belt.
9. Remove the crankshaft/vibration damper pulley and hub.
10. Remove the bolts and coolant supply pipe coming out of the front of the cylinder head from the water pump. Remove the O-ring from the pipe and move the pipe to the side.
11. Loosen the nut and remove the bolt securing the front engine lifting eye located on the front side of the cylinder head (see Fig. Location of coolant supply pipe and engine lifting eye mounting bolt).
12. On models with self-leveling rear suspension, loosen the clamp and remove the hose from the pipe on the left front side of the cylinder head. Close the hose and pipe with the appropriate plugs.
13. Remove the upper drive chain cover.
14. Loosen the center power steering pump bracket mounting bolt, then remove the three bracket mounting bolts (see Fig. Power Steering Pump Bracket Fastening Elements).
15. Rotate the bracket to release the lower drive chain cover.
16. Remove the two bolts securing the power steering pump to the bracket and move the pump to the side.
17. Remove the bolts and remove the radiator fan pulley bracket from the timing chain cover (see Fig. Location of radiator fan pulley bracket mounting bolts).
18. Unscrew the nut and remove the crankshaft angle sensor located on the front side of the drive chain cover from the bracket. Remove the sensor wires and mounting brackets and move the sensor to the side.
19. Disconnect the electrical wires from the generator.
20. Unscrew the four bolts securing the generator bracket to the engine and remove the generator together with the bracket.
21. Remove the drive chain tensioner mechanism.
22. Working underneath the vehicle, remove the bolts securing the oil pan to the lower timing chain cover (see Fig. Location of oil pan to lower drive chain cover bolts). Note the position of the bolts as they are different sizes. On models with a self-leveling rear suspension system, move the system hose to the side.
23. Remove the remaining bolts securing the lower drive chain cover. Note their locations as they vary in size (see Fig. Location of remaining bolts securing the lower drive chain cover).
24. Carefully remove the lower drive chain cover from the guide pins.
Installation
1. Clean the mating surfaces of the cylinder block and the lower and upper timing chain covers.
2. Check the condition of the oil pan gasket and if damaged, replace the oil pan gasket.
3. If necessary, replace the front crankshaft seal ring installed in the lower timing chain cover.
4. Using a screwdriver blade, remove the old O-ring from the timing chain cover.
5. Clean the sealing ring seat.
6. Using a tubular drift, install a new O-ring into the timing chain cover.
7. To protect the crankshaft seal lips when installing the timing chain cover, wrap adhesive tape around the front end of the crankshaft.
8. Replace the gasket in the timing chain cover at the lower radiator fan bracket mounting bolt hole.
9. Apply a thin layer of sealant to the mating surfaces of the cylinder block and lower timing chain cover.
10. Lubricate the crankshaft seal lips with clean engine oil and carefully install the lower timing chain cover onto the cylinder block.
11. Install the drive chain cover mounting bolts shown in the illustration Location of the remaining lower drive chain cover mounting bolts and tighten them to the specified torque.
12. Remove the adhesive tape from the front end of the crankshaft.
13. Install the oil pan to lower timing chain cover bolts and tighten to the specified torque.
14. Install the drive chain tensioner mechanism.
15. Install the generator with the bracket on the engine and screw the bolts, tightening them to the required torque. Connect the electrical wires to the generator.
16. Install the crankshaft angle sensor and secure it with the nut.
Caution: When installing a new lower timing chain cover, the position of the crankshaft angle sensor must be checked and, if necessary, adjusted.
17. Install the radiator fan bracket and secure with bolts, tightening them to the specified torque.
18. Install the power steering pump in place and secure with bolts.
19. Apply a thin bead of sealant to both sides of the timing chain cover bolt located on the power steering mounting bracket.
20. Rotate the power steering pump bracket and secure with bolts, then tighten the center mounting bolt.
21. Install the upper drive chain cover.
22. If equipped, connect the rear self-leveling suspension hose to the pipe on the front side of the cylinder head.
23. Install the bolt and nut securing the front engine lifting eye.
24. Install a new O-ring onto the coolant supply pipe, install the pipe onto the pump and secure with bolts.
25. Install the crankshaft pulley/vibration damper and hub.
26. Install the accessory drive belt pulleys and accessory drive belt.
27. Install the air intake pipe and secure it with a bolt.
28. Install the fan impeller and radiator.
29. Install the air filter.
30. Install the lower engine splash shield.
31. Add coolant to the cooling system.
32. Check the engine oil level and top it up if necessary.
33. Connect the ground wire to the battery.