SAFARI

ENGINE

TIMING HOUSING COVER

Timing Gear cover removal

Remove engine cover.

Drain the coolant from the radiator.

Remove radiator and intercooler as per the

given procedure.

Slacken and remove all the belts as per the

belt removal procedure.

Lock the crankshaft at flywheel and remove

crank shaft pulley mounting bolts.

Unlock the bolts for mounting water pump

pulley and remove the water pump pulley.

Pull out the pulley using a 3 legged puller with

spacer.

Remove the electric connector on the cam sensor

and unscrew the screw holding the cam sensor.

Remove the cam sensor.

10. Remove the M6 screws (4 Nos.) used for

mounting the noise cover.

11. Remove the noise shield on the timing gear

housing.

Timing Cover Installation

Fit new oil seal on the cover using drift 312 589

1239 as shown in fig.13. It is advisable to apply

sealing compound on outer diameter of seal

before assembly.

Examine the spacer on crankshaft for wear and

replace if necessary.

Stick new gasket to the cover by using sealing

compound.

Apply grease on the oil seal lip and fit cover

carefully without damaging the oil seal lip.

Tighten the cover screws to specified torque.

Fit the noise shield on timing gear cover and

tighten the screws.

Install the crankshaft pulley and the thrust

washer.

Tighten the mounting bolt to specified torque.

Unlock the crankshaft at the flywheel end.

10. Fit cam sensor.

11. Fit the water pump pulley and tighten the bolts.

12. Mount poly-V belt and V-belt as per the belt

fitment procedure. Set the belt tensions as per the

procedure.

13. Install radiator and intercooler as per fitment

procedure.

14. Fill coolant from the radiator cap.

15. Connect the cam sensor connector after filling

coolant so that water does no fall on the

connectors.

16. Check engine for water / oil leakages after test

run and rectify if necessary.

17. Fit engine cover.

Noise Reduction Covers

Noise shield with foam on front timing gear cover.

1 Boss for cam sensor fitment

2 Timing gear noise shield