Relieve the fuel system pressure, then disconnect the negative battery cable. Loosen the water pump pulley bolts, remove the drivebelt and drivebelt idler pulley, and then remove the water pump pulley. Remove the fuel injection high pressure pump and housing. Remove the crankshaft pulley, ensuring the engine remains at TDC with the valve cover removed. Disconnect the Crankshaft Position (CKP) sensor electrical connector and remove the sensor, noting that a new sensor must be installed each time it is removed, along with a special alignment tool. Remove the power steering hose bracket fastener and bracket from the bottom of the cover. Support the engine from above with an engine support fixture and raise it enough to remove the right engine mount. Unbolt and set aside the power steering pump without disconnecting the hoses, then remove the pump bracket bolts and bracket. Remove the crankshaft front oil seal and the timing cover. Installation is the reverse of removal, ensuring to clean the mating surfaces of all sealant, install the engine cover within ten minutes of applying a 2.5 mm bead of RTV sealant, tighten the bolts in sequence to the torque specifications, install a new crankshaft front oil seal, verify proper crankshaft/camshaft timing, and install a new CKP sensor with the necessary alignment tool, not tightening the sensor mounting bolts until the installation tool is in place. For the timing chain and tensioner, remove the timing cover, compress the timing chain tensioner, and place a pin into the hole to hold it in the compressed position, being cautious to compress only the round plunger and not the ratchet mechanism. Remove the two tensioner mounting bolts and then the tensioner, followed by the loose timing chain guide and timing chain. The left chain guide and camshaft sprockets can be removed if necessary. Remove the camshaft alignment tool if installed, loosen both camshaft phaser and sprocket bolts without removing them, and use a wrench on the hexagonal area of the camshaft to hold it while turning the camshaft sprocket. Install the left chain guide if removed, then the timing chain, followed by the right chain guide. Install the timing chain tensioner and tighten the fasteners to the torque specifications, removing the pin to release the tensioner to engage the chain guide. Install the camshaft alignment tool, hold the camshafts in place with a wrench on the hex surface, and tighten the camshaft sprocket bolts to the torque specifications. Finally, install the timing cover, install the fuel injection pump housing ensuring the camshaft lobe is at its lowest point, and complete the remainder of the installation in reverse order.
