Operation CHARM: Car repair manuals for everyone.

Lower Timing Chain Cover






Lower Timing Chain Cover

Special tools, testers and auxiliary items required

Hand drill with plastic brush attachment

Protective eye-wear

Removing

Transmission removed.

Engine oil drained.


Risk of injury.

The lock carrier must be installed and the torque support must be securely attached.

- Remove the drive plate => [ Drive Plate ] Drive Plate.

- Remove the left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Remove the oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.

- Remove the bolts - arrows -.






- Remove bolts - 1 and 2 - and - 4 through 9 -.

- Carefully remove the lower cover for the timing chain from the bond.

- Press the transmission side of the crankshaft shaft seal out of the lower timing chain cover.

Ignore - 3 -.

Installing

Replace seals, gaskets and O-rings.

During installation, all cable ties must be installed at the same location.

- Remove the right upper alignment bushing from the cylinder block.

- Grind the alignment bushing down at an angle as shown in the illustration.






Dimension - x - = 6.5 mm.

Dimension - y - = 8 mm.

- Insert the alignment bushing in the cylinder block so the angled side faces up.

Because of the chamfer, the lower timing chain cover can be positioned more easily when the cylinder head is installed.


Risk of eye injury.

Wear protective eye-wear.


Risk of contaminating lubricating system.

Cover open parts of engine.

- Remove the sealant residue on the cover for the timing chain, cylinder block and cylinder head, for example using a rotating plastic brush.






- Clean the sealing surfaces; they must be free of oil and grease.

- Clean the old sealant off the holes - arrow - in the cylinder head gasket.






With cylinder head installed, holes in cylinder head seal are only half visible.


The cylinder head seal could be damaged.

Only bend ends of cylinder head seals slightly, do not kink.

A kinked cylinder head seal must be replaced.

- Bend the end of the cylinder head seals down slightly - arrows - until the upper sealing surface of the seals and the cylinder head can be cleaned.






- Clean the upper and lower cylinder head gaskets; they must free from oil and grease.

Note the expiration date of the sealing compound.

- Cut the tube nozzle at the front marking (nozzle diameter approximately 2 mm).






The sealant must be applied to several places on the engine, as described in the following.

- Lightly coat the top and bottom cylinder head seal sealing surfaces with lubricant by bending the seals down slightly again - arrows -.






- Use a flat object such as a feeler gauge to coat the surface between the cylinder head and seal.

- Fill the cleaned cylinder head seal holes - arrow - with sealant.







The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than indicated.

- Apply sealant beads - 1 through 4 - on the clean lower timing chain cover sealing surfaces as shown in the illustration.






The groove of sealing surface must be completely filled with sealant.

The sealant beads must be 1.5 to 2.0 mm above the sealing surface.

The sealant bead - 2 - must be drawn through as shown in the illustration even though the groove is intermittent.

The timing chain cover must be installed within 5 minutes after applying the sealant

- Insert the sealing rings - arrows - into the grooves on the lower timing chain cover.

- Position the lower timing chain cover, guiding it diagonally from below to the sealing surface on the cylinder block and cylinder head.






- When positioning, ensure the cylinder head seals are not damaged.

- Tighten the bolts for the lower timing chain cover. Refer to => [ Lower Timing Chain Cover, Tightening
Specifications and Sequence ] Timing Chain Covers Overview.

The rest of the installation is performed in reverse order of removal, noting the following:

- Install the oil filter housing. Refer to => [ Oil Filter Housing ] Oil Filter Housing.

- Install the left and right timing chain covers. Refer to => [ Left and Right Timing Chain Covers ] Left and Right Timing Chain Covers.

- Install the transmission-side crankshaft shaft seal. Refer to => [ Crankshaft Seal, Transmission Side ] Service and Repair.

- Installing drive plate. Refer to => [ Drive Plate ] Drive Plate.

- Fill engine oil and check oil level.