407991-1611 ZEXEL Cross 4079911611

Start By:a. remove automatic timing advanceb. remove oil panc. remove water pumpd. remove crankshaft front seal and wear sleeve 1. Disconnect clip (1) for the wiring harness.2. Remove connector (2) from the clip. 3. Fasten Tooling (A) and a hoist to the timing gear cover. The weight of the timing gear cover is 18 kg (40 lb).4. Use Tooling (B) to remove studs (3).5. Move fuel overflow tube (4) out of the way.6. Remove cover (5) and the gasket.7. Disconnect all wiring harness clips from the timing gear housing, and move the wiring harness out of the way.8. Remove the bolts that hold the timing gear cover to the cylinder block, and remove the timing gear cover.9. Remove the gasket for the timing gear cover.10. Thoroughly clean the gasket surface of the cylinder block and the timing gear cover. Be careful not to scratch or mar the gasket surface of the aluminum timing gear cover.Install Timing Gear Cover
1. Install new O-ring seal (1) on the fuel injection pump housing. Put clean engine oil on the O-ring seal.2. Put new gasket (2) in position on the cylinder block. Engage the gasket with the two dowels. Use clean 2S-3230 Bearing Lubricant to hold the gasket in place on the cylinder block. 3. Put the timing gear cover in position on the dowels. Install the bolts that hold the timing gear cover to the cylinder block.4. Install cover (6), and a new gasket.5. Connect the wiring harness clips to the timing gear housing.6. Connect the clip that holds fuel overflow tube (5).7. Use Tooling (B) to install studs (3).8. Remove Tooling (A).9. Put 5P-3413 Pipe Sealant with "Teflon" on the threads of stud (4). Use Tool (B) to install stud (4) to a height of 28.96 mm (1.140 in).10. Install the clip that holds the wiring harness.11. Install the connector in the clip.12. Trim gasket (2) even with the oil pan surface of the cylinder block and timing gear cover.End By:a. install crankshaft front seal and wear sleeveb. install water pumpc. install oil pand. install automatic timing advance