Contents: Dismantling ⇩ Assembly ⇩
Before disconnecting the battery, make sure that all requirements and conditions contained in the section on disconnecting the battery are met.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Place the vehicle on a lift.
2. Disconnect the negative battery terminal.
3. Remove the cooling system pump.
COOLING SYSTEM: V8 engine, REPAIR WORK, Cooling system pump gasket.
4. Remove the upper front timing cover on the left head.
V8 Engine, REPAIR WORK, Upper Front Timing Belt Cover Left Cylinder Head.
5. Remove the upper front timing cover on the right head.
V8 Engine, REPAIR WORK, Upper Front Timing Belt Cover Right Cylinder Head.
6. Remove the front crankshaft oil seal.
V8 engine, REPAIR WORK, Front crankshaft oil seal.
7. Unscrew the 2 bolts securing the accessory drive belt tensioner to the lower timing mechanism cover.
8. Remove the dust cover from the belt roller and unscrew the Torx bolt securing the belt roller.
9. Remove the accessory drive belt tensioner.
10. Loosen the nut and disconnect the battery cable from the generator.
11. Disconnect the battery cable from the lower timing belt cover.
12. Unscrew the 6 generator mounting bolts and the generator harness clamp.
13. Remove the generator from the lower timing cover.
14. Discard the generator O-ring.
15. Unscrew 2 bolts and 1 nut securing the power steering pump and move the pump to the side.
16. Remove the 6 bolts securing the lower timing belt cover to the upper part of the oil pan.
17. Unscrew the 15 bolts securing the lower timing belt cover to the cylinder block.
- A = M8 x 75 mm
- B = M6 x 40 mm
- B = M6 x 85 mm
- B = M6 x 80 mm
- A = M8 x 90 mm
- B = M6 x 60 mm
NOTE: Note the position of all mounting bolts.
18. Remove the lower front timing gear cover.
19. Discard the 3 lower timing cover gaskets.
Assembly
1. Wipe the timing cover and mating surface, pins and pin seats.
2. Apply STC 50550 sealant to the areas shown in the figure.
3. Install 3 new lower timing cover gaskets.
4. Install the lower front timing cover.
5. Screw in 15 bolts securing the lower timing cover to the cylinder block and pre-tighten them to a torque of 5 N·m.
6. Tighten the M6 bolts securing the bottom cover to a torque of 10 N·m, and the M8 bolts to a torque of 22 N·m.
CAUTION: After tightening all bolts, check their tightening torque.
7. Install the 6 bolts securing the lower timing belt cover to the upper oil pan and tighten to 12 Nm.
8. Install the power steering pump on the bracket, screw in the mounting bolts and screw on the nut. Tighten the bolts to 10 N·m and the nut to 25 N·m.
9. Wipe the mating surfaces of the generator and the timing cover.
10. Lubricate the new O-ring and install it on the generator.
11. Install the generator and tighten the mounting bolts.
12. Secure the battery cable to the lower timing belt cover.
13. Connect the battery cable to the generator and tighten the cable mounting nut to a torque of 13 N·m.
14. Install the accessory drive belt tensioner, screw in the idler pulley mounting bolt and tighten it.
15. Place the dust cap on the tensioner idler pulley.
16. Install the 2 bolts securing the accessory belt tensioner to the lower timing belt cover, but do not tighten them yet.
17. Install the front crankshaft oil seal.
V8 engine, REPAIR WORK, Front crankshaft oil seal.
18. Install the upper front timing cover onto the right cylinder head.
V8 Engine, REPAIR WORK, Upper Front Timing Belt Cover Right Cylinder Head.
19. Install the upper front timing cover onto the left cylinder head.
V8 Engine, REPAIR WORK, Upper Front Timing Belt Cover Left Cylinder Head.
20. Install the cooling system pump.
COOLING SYSTEM: V8 engine, REPAIR WORK, Cooling system pump gasket.
21. Connect the negative battery terminal.
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