SAFARI

ENGINE 50 1 2 TIMING HOUSING COVER Timing Gear cover removal 1. Remove engine cover. 2. Drain the coolant from the radiator. 3. Remove radiator and intercooler as per the given procedure. 4. Slacken and remove all the belts as per the belt removal procedure. 5. Lock the crankshaft at flywheel and remove crank shaft pulley mounting bolts. 6. Unlock the bolts for mounting water pump pulley and remove the water pump pulley. 7. Pull out the pulley using a 3 legged puller with spacer. 8. Remove the electric connector on the cam sensor and unscrew the screw holding the cam sensor. 9. 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 1. 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. 2. Examine the spacer on crankshaft for wear and replace if necessary. 3. Stick new gasket to the cover by using sealing compound. 4. Apply grease on the oil seal lip and fit cover carefully without damaging the oil seal lip. 5. Tighten the cover screws to specified torque. 6. Fit the noise shield on timing gear cover and tighten the screws. 7. Install the crankshaft pulley and the thrust washer. 8. Tighten the mounting bolt to specified torque. 9. 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