Special Tools

EN 46109 Engine Front Cover Installation Guide Pins

1. Remove the engine cover. Refer to Fuel Injector Sight Shield Replacement .
2. Remove the upper intake manifold with the lower intake manifold. Refer to Lower Intake Manifold Replacement .
3. Remove the camshaft covers. Refer to Camshaft Cover Replacement - Left Side and Camshaft Cover Replacement - Right Side .
4. Drain the engine coolant. Refer to Cooling System Draining and Filling .
5. Disconnect the purge vent hose from the water outlet.
6. Remove the water outlet with the radiator hose and reposition aside. Refer to Water Outlet Housing Replacement .
7. Remove the accessory drive belts. Refer to Water Pump and Generator Belt Replacement and Air Conditioning Compressor and Power Steering Pump Belt Replacement .
8. Remove the A/C compressor and power steering belt tensioner. Refer to Air Conditioning Compressor and Power Steering Pump Belt Tensioner Replacement .
9. 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.

10. Remove the power steering fluid reservoir and reposition the power steering fluid reservoir in order to provide access.
11. Remove the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement .

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

12. Remove the power steering pump upper front bolt and loosen the remaining two bolts. Refer to Power Steering Pump Pulley Replacement .
13. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal .
14. 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 .
15. 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 .



16. Remove the engine front cover with the water pump. Refer to Engine Front Cover Removal .
17. 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.

18. 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.

19. Carefully clean the engine front cover sealing surfaces. Refer to Engine Front Cover Cleaning and Inspection .
20. 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).

1. Assemble the engine front cover as necessary. Refer to Engine Front Cover Assemble .



2. Use the EN 46109 in order to install the engine front cover. Refer to Engine Front Cover Installation .
3. 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 .
4. 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 .
5. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation .
6. Install the power steering pump. Refer to Power Steering Pump Pulley Replacement .
7. Install the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement .
8. Install the power steering fluid reservoir. Refer to Remote Power Steering Fluid Reservoir Replacement .
9. Install the generator bracket with the generator and the belt tensioner. Refer to Generator Bracket Replacement .
10. Install the A/C compressor and power steering belt tensioner. Refer to Air Conditioning Compressor and Power Steering Pump Belt Tensioner Replacement .
11. Install the accessory drive belts. Refer to Air Conditioning Compressor and Power Steering Pump Belt Replacement and Water Pump and Generator Belt Replacement .
12. Install the water outlet. Refer to Water Outlet Housing Replacement .
13. Install the purge vent hose to the water outlet.
14. Fill the cooling system. Refer to Cooling System Draining and Filling .
15. Install the camshaft covers. Refer to Camshaft Cover Replacement - Left Side and Camshaft Cover Replacement - Right Side .
16. Install the upper intake manifold with the lower intake manifold. Refer to Lower Intake Manifold Replacement .
17. Install the engine cover. Refer to Engine Front Cover Installation .
18. Fill the cooling system. Refer to Cooling System Draining and Filling .