Special Tools
EN 46109
Engine Front Cover Installation Guide Pins
Removal Procedure
- Remove the engine cover. Refer to
Fuel Injector Sight Shield Replacement
.
- Remove the upper intake manifold with the lower intake manifold. Refer to
Lower 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
Water Outlet Housing Replacement
.
- Remove the accessory drive belts. Refer to
Water Pump and Generator Belt Replacement
and
Air Conditioning Compressor and Power Steering Pump Belt Replacement
.
- Remove the A/C compressor and power steering belt tensioner. Refer to
Air Conditioning Compressor and Power Steering Pump Belt Tensioner Replacement
.
- Remove the generator bracket with the generator and the belt tensioner. Refer to
Generator Bracket Replacement
.
Important: 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.
- Remove the power steering pump pulley. Refer to
Power Steering Pump Pulley Replacement
.
Important: Do not disconnect the power steering pipes/hoses.
- Remove the power steering pump upper front bolt and loosen the remaining two bolts. Refer to
Power Steering Pump Pulley 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 Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Intake
,
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Exhaust
,
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Intake
, and
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Exhaust
.
- Remove the engine front cover with the water pump. Refer to
Engine Front Cover Removal
.
- Disassemble the engine front cover as necessary. Refer to
Engine Front Cover Disassemble
.
Important: 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
.
Important: 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 as necessary. Refer to
Engine Front Cover Assemble
.
- Use the
EN 46109
in order
to install the engine front cover. Refer to
Engine Front Cover Installation
.
- Install the camshaft position actuator solenoid valves to the front cover. Refer to
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Intake
,
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Exhaust
,
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Intake
, and
Camshaft Position Actuator Solenoid 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 power steering pump. Refer to
Power Steering Pump Pulley Replacement
.
- Install the power steering pump pulley. Refer to
Power Steering Pump Pulley Replacement
.
- Install the power steering fluid reservoir. Refer to
Remote 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. Refer to
Air Conditioning Compressor and Power Steering Pump Belt Tensioner Replacement
.
- Install the accessory drive belts. Refer to
Air Conditioning Compressor and Power Steering Pump Belt Replacement
and
Water Pump and Generator Belt Replacement
.
- Install the water outlet. Refer to
Water Outlet Housing Replacement
.
- 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 upper intake manifold with the lower intake manifold. Refer to
Lower Intake Manifold Replacement
.
- Install the engine cover. Refer to
Engine Front Cover Installation
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
.