Timing Cover: Service and Repair
FRONT CASE
COMPONENTS
DISASSEMBLY
1. Remove the timing belt. Refer to "Timing Belt." Service and Repair
2. Remove all the oil pan bolts.
3. Tap the oil pan with a rubber hammer and remove the pan. (upper and lower parts)
4. Remove the oil screen and gasket.
5. Remove the front case assembly.
6. Remove the oil pressure switch.
7. Remove the oil filter bracket and gasket.
8. Using the special tool (09213-33000) remove the plug cap from the oil pump portion of the front case.
9. Remove the plug on the left side of the cylinder block and insert a screw driver with an 8 mm (0.32 inch) diameter into the plug hole. The screwdriver must be inserted more than 60 mm (2.4 inch)
10. Remove the oil pump driven gear and the left counter balance shaft retaining bolt.
l1. Remove the front case mounting bolts and remove the front case assembly and gasket and then remove the two counter balance shafts from the cylinder block.
12. Remove the oil pump cover from the front case.
13. Remove the oil pump gears from the front case.
14. Remove the screw driver. (Step 9)
INSPECTION
1. Check all oil holes for clogging. Clean the holes if necessary.
2. Check the counter balance shaft front bearing for wear, damage and seizure. If there is anything wrong with the bearing, replace the front case.
3. Check the front case for cracks and other damage.
4. Replace a cracked or damaged front case.
COUNTER BALANCE SHAFT
1. Check the journals for wear or seizure.
2. If excessive wear or seizure is evident, check the bearing carefully.
3. If necessary, replace the counter balance shaft bearing or the shaft itself.
OIL SEAL
1. Check the oil seal lip for wear and damage. Replace the oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace the oil seal if necessary.
OIL PRESSURE SWITCH
1. Check the continuity between the terminal and the body with an ohmmeter.
If there is no continuity, replace the oil pressure switch.
2. Check the continuity between the terminal and the body when the fine wire is pushed. If there is continuity even when the fine wire is pushed,replace the switch.
3. If there is no continuity when a 50 kPa (7 psi) vacuum is applied through the oil hole, the switch is operating properly. Check for an air leak. If air leaks, the diaphragm is broken. Replace the switch.
OIL PUMP
1. Assemble the oil pump gear to the front case and rotate it to verify smooth rotation with no looseness.
2. Make sure that there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump cover.
3. Install the drive and driven gears to the front case. Measure the tip clearance of the gears.
[Standard value]
Drive gear: 0.16 - 0.21 mm (0.0063 - 0.0083 inch)
Driven gear: 0.18 - 0.21 mm (0.0071 - 0.0083 inch)
[Limit]
Drive gear: 0.25 mm (0.0098 inch)
Driven gear: 0.25 mm (0.0098 inch)
4. Check the side clearance.
[Standard value]
Drive gear: 0.08 - 0.14 mm (0.0031 - 0.0055 inch)
Driven gear: 0.06 - 0.12 mm (0.0024 - 0.0047 inch)
[Limit]
Drive gear: 0.25 mm (0.0098 in)
Driven gear: 0.25 mm (0.0098 inch)
COUNTER BALANCE SHAFT BEARING
REPLACEMENT
1. Using a special tool, remove the front bearing of the right counter balance shaft from the cylinder block.
2. Using a special tool, remove the rear bearing of the right counter balance shaft from the cylinder block.
3. Using a special tool, remove the rear bearing of the left counter balance shaft from the cylinder block. At this time, install a special tool on the front surface of cylinder block to hold the bearing puller.
4. Using a special tool, install the rear bearing of the left counter balance shaft to the cylinder block.
NOTE:
1. Apply engine oil to the outside of rear bearing and bearing hole in cylinder block.
2. The led rear bearing has no oil holes.
5. Using a special tool, install the rear bearing of the right counter balance shaft to the cylinder block.
NOTE:
1. Apply engine oil to the outside surface of the bearing.
2. Make sure that the bearing oil hole is aligned with the oil hole of cylinder block.
6. Using a special tool, install the front bearing of the right counter balance shaft to the cylinder block.
NOTE: Make sure that the bearing oil hole is aligned with the oil hole cylinder block.
REASSEMBLY
1. Apply engine oil to the gear and align the two timing marks.
2. Using the special tool, the crankshaft front oil seal installer (09214-32000), install the crankshaft front oil seal into the front case.
3. Set the special tool (09214-32100) on the front end of the crankshaft and apply a thin coat of engine oil to the outer circumference of the special tool to install the front case.
4. Install a new front case gasket to the front case assembly and tighten the flange bolts temporarily.
5. Install the front case assembly with a new gasket. Tighten bolts to the specified torque.
Front case assembly
Tightening torque: 20 - 27 Nm (200 - 270 kg-cm, 14 - 20 ft. lbs.)
6. Insert a screwdriver into the plug hole in left side of cylinder block. After verifying that the shaft is in the proper position, replace the bolt and tighten it.
7. Install a new O-ring to the groove of the front case.
8. Using a special tool, install the plug case and tighten it to the specified torque.
Plug cap
Tightening torque: 20 - 27 Nm (200 - 270 kg-cm, 14 - 20 ft. lbs.)
9. Apply sealant to the groove of the pan flange as shown.
NOTE:
1. Apply sealant approximately 4 mm (0.16 inch) in thickness.
2. After the application of the sealant, install the oil pan within 15 minutes.
10. Note the difference in bolt lengths at the locations shown. Install the upper and lower oil pans and tighten the bolts to the specified torque.
Tightening torque
Oil pan bolt: 10 - 12 Nm (100 - 120 kg-cm, 7 - 9 ft. lbs.)
11. Using a 24 mm deep socket, install the oil pressure switch after applying sealant to the threaded area.
Sealant: Threebond 1104 or equivalent
NOTE: Do not torque the oil pressure switch excessively.
Tightening torque
Oil pressure switch: 8 - 12 Nm (80 - 120 kg-cm, 6 - 9 ft. lbs.)