Document ID: 2196312

Special Tools

EN 46109 - Engine Front Cover Installation Guide Pins

For equivalent regional tools, refer to Special Tools.

Removal Procedure

Remove the engine cover. Intake Manifold Cover Replacement - Rear.
Remove the intake manifold. Refer to Intake Manifold Replacement.
Remove the camshaft covers. Refer to Camshaft Cover Replacement - Left Side and Camshaft Cover Replacement - Right Side.
Drain the engine coolant. Refer to Cooling System Draining and Filling.
Disconnect the purge vent hose from the water outlet.
Remove the water outlet with the radiator hose and reposition aside. Refer to Radiator Outlet Hose Replacement
Remove the accessory drive belts. Refer to Drive Belt Replacement
Remove the A/C compressor and power steering belt tensioner. Refer to Drive Belt Tensioner Replacement
Remove the generator bracket with the generator and the belt tensioner. Refer to Generator Bracket Replacement.

Note: Do not disconnect the power steering pipes or drain the power steering fluid.

Remove the power steering fluid reservoir and reposition the power steering fluid reservoir in order to provide access. Refer to Power Steering Fluid Reservoir Bracket Replacement

Note: Do not disconnect the power steering pipes/hoses.

Remove the power steering pump upper front bolt and loosen the remaining two bolts.
Remove the starter. Refer to Starter Replacement.
Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal.
Remove the camshaft position sensors. Refer to Camshaft Position Sensor Replacement - Bank 2 (Left Side) Exhaust , Camshaft Position Sensor Replacement - Bank 2 (Left Side) Intake , Camshaft Position Sensor Replacement - Bank 1 (Right Side) Exhaust and Camshaft Position Sensor Replacement - Bank 1 (Right Side) Intake.
Remove the camshaft position actuator solenoid valves from the front cover. Refer to Camshaft Position Actuator Valve Solenoid Replacement - Bank 1 (Right Side) Intake , Camshaft Position Actuator Valve Solenoid Replacement - Bank 1 (Right Side) Exhaust , Camshaft Position Actuator Valve Solenoid Replacement - Bank 2 (Left Side) Intake , and Camshaft Position Actuator Valve Solenoid Replacement - Bank 2 (Left Side) Exhaust.
Remove the engine front cover with the water pump. Refer to Engine Front Cover Removal.

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Disassemble the engine front cover. Refer to Engine Front Cover Disassemble.

Note: Do NOT use sharp and/or metal gasket scrapers in order to clean the sealing surfaces.

Carefully clean the engine front cover sealing surfaces. Refer to 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.

Carefully clean the engine front cover sealing surfaces. Refer to Engine Front Cover Cleaning and Inspection.
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

Assemble the engine front cover. Refer to Engine Front Cover Assemble.
Use the EN 46109 - engine front cover installation guide pins in order to install the engine front cover. Refer to Engine Front Cover Installation.

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Install the camshaft position actuator solenoid valves to the front cover. Refer to Camshaft Position Actuator Valve Solenoid Replacement - Bank 1 (Right Side) Intake , Camshaft Position Actuator Valve Solenoid Replacement - Bank 1 (Right Side) Exhaust , Camshaft Position Actuator Valve Solenoid Replacement - Bank 2 (Left Side) Intake , and Camshaft Position Actuator Valve Solenoid Replacement - Bank 2 (Left Side) Exhaust.
Install the camshaft position sensors. Refer to Camshaft Position Sensor Replacement - Bank 2 (Left Side) Exhaust , Camshaft Position Sensor Replacement - Bank 2 (Left Side) Intake , Camshaft Position Sensor Replacement - Bank 1 (Right Side) Exhaust and Camshaft Position Sensor Replacement - Bank 1 (Right Side) Intake.
Install the crankshaft balancer. Refer to Crankshaft Balancer Installation.
Install the starter. Refer to Starter Replacement.
Install the power steering pump.
Install the power steering pump pulley.
Install the power steering fluid reservoir. Refer to Power Steering Fluid Reservoir Replacement.
Install the generator bracket with the generator and the belt tensioner. Refer to Generator Bracket Replacement.
Install the A/C compressor and power steering belt tensioner.
Install the accessory drive belts.
Install the water outlet.
Install the purge vent hose to the water outlet.
Fill the cooling system. Refer to Cooling System Draining and Filling.
Install the camshaft covers. Refer to Camshaft Cover Replacement - Left Side and Camshaft Cover Replacement - Right Side.
Install the intake manifold. Refer to Intake Manifold Replacement.
Install the engine cover. Refer to Intake Manifold Cover Replacement - Rear.
Fill the cooling system. Refer to Cooling System Draining and Filling.

Operation	Task	Skill	Hours
Remove & Replace	Camshaft & Timing · Front Cover, R&R	B	5.9
Remove & Replace	Crankshaft & Bearings · Front Crank Seal, R&R	B	1.3
Remove & Replace	Crankshaft & Bearings · Front Crank Seal, R&R · NOTE · To Bleed P/S System, Add		0.3
Replace	Front Cover	B	7.5

Timing Cover