Lower Timing Chain Cover

Lower Timing Chain Cover

Special tools, testers and auxiliary items required

• Engine Support Bridge (T40150)

• Hand drill with plastic brush attachment

• Protective eyewear

• Sealant

• Stud extractor, commercially available

Removing

• The transmission is removed.

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

- Install protective body covers. Refer to => [ Protective Body Covers, Installing ] Protective Body Covers, Installing.

- Remove the left - 1 - and right - 3 - engine compartment trim.





- Remove engine cover - 2 -.

- Bring the rear lid into the service position.





- Drain the coolant in the engine. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Drain engine oil.





- Remove the flywheel. Refer to => [ Flywheel ] Flywheel.

- Remove the power steering pump.





- Remove the drive-through shaft.





- Remove.





- Remove the rear coolant pipe. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.

- Remove the secondary air injection combination valves. Refer to: Left => [ Secondary Air Injection Left Combination Valve ] Secondary Air Injection Left Combination Valve, right => [ Secondary Air Injection Right Combination Valve ] Secondary Air Injection Right Combination Valve.

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

- Remove the secondary air injection pump. Refer to => [ Secondary Air Injection Pump ] Service and Repair.

- Install the Engine Support Bridge (T40150) parts as illustrated, placing the left Support (T40150/1) and right Support (T40150/2) on the body braces.





• The tab on the (T40150/1) and (T40150/2) must be inserted in the body brace - arrow 1 -.

• The retainer on the side of the (T40150/1) and (T40150/2) must lie on the body brace - arrow 2 -.

• The Connector (T40150/5) bolts must engage in the holes in the Square Tube (T40150/3) and be installed completely.

- Engage the Spindle Carabiner Hooks (T40150/6) on the front engine lifting eyes.

- Install additional Engine Support Bridge (T40150) with the Spindle (T40150/7) as illustrated.





• The Connector (T40150/5) bolts must engage in the holes in the Square Tube (T40150/4) and be installed completely.

- Engage the Spindle (T40150/7) on the right rear engine lifting eye.

- Remove engine bracket left and right bolts - arrows -.





- Raise the engine evenly and press it to the right slightly.

- Remove nuts - 6 through 1 -.





- Remove the exhaust manifold with catalytic converter from the cylinder head and lay aside.

- Remove the bolts - 1 through 8 - and then carefully remove the left cover for the timing chain from the bond.





- Remove the bolts - 1 through 8 - and then carefully remove the right cover for the timing chain from the bond.





- Remove the studs - arrows - with a commercially available stud extractor.





- Remove bolts - arrows -.





- Remove bolts - 1 through 10 - and remove the lower timing chain cover.

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

Installing

Installation is in reverse order of removal, note the following:

- 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.

- Install the alignment bushing on 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.

CAUTION!
Risk of eye injury.

• Wear safety glasses.

CAUTION!
Risk of contaminating lubricating system.

• Cover open parts of engine.

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





- Clean sealing surfaces, must be free of oil and grease.

- Clean old sealant out of the holes - arrow - in the cylinder head seals.





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

CAUTION!
The cylinder head seal could be damaged.

• In the following steps, only bend the ends of the cylinder head seals slightly. Do not kink them.

• 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 top and bottom of the cylinder head seals so they are free of oil and grease.

• Note the expiration date of the sealing compound.

- Cut tube nozzle at front marking (jet dia. approximately 2 mm).





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





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





- To coat the surface between the cylinder head and seal, use a flat object, for example a feeler gauge.

CAUTION!
The lubrication system could be plugged with excess sealant.

• Do not apply sealant bead thicker than specified.

- Apply sealant beads - 1 through 9 - on the clean lower timing chain cover sealing surfaces as shown in the illustration.





• Thickness of sealant beads: 2.5 mm.

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

- 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. Refer to => [ Lower Timing Chain Cover, Tightening Specifications
and Sequence ] Timing Chain Covers Assembly Overview.

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

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

- Install the studs with a commercially available stud extractor until dimension - a - is reached.





• Dimension - a - = 35 ± 1 mm.

- Install the left timing chain covers: Left => [ Installing ] Left Timing Chain Cover, right => [ Installing ] Right Timing Chain Cover.

- Install the left exhaust manifold with catalytic converter. Refer to => [ Left Exhaust Manifold with Catalytic Converter ] Left Exhaust Manifold With Catalytic Converter.

- Install engine bracket. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.

- Install secondary air injection (AIR) pump. Refer to => [ Secondary Air Injection Pump ] Service and Repair.

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

- Install the secondary air injection combination valves. Refer to: Left => [ Secondary Air Injection Left Combination Valve ] Secondary Air Injection Left Combination Valve, right => [ Secondary Air Injection Right Combination Valve ] Secondary Air Injection Right Combination Valve.

- Install the rear coolant pipes. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.

- Install the engine compartment crossmember. Refer to => [ Engine Compartment Crossmember ] Engine Assembly.

- Install intake manifold.

- Install the drive-through shaft.

- Install power steering pump.

- Install the flywheel. Refer to => [ Flywheel ] Flywheel.

- Install air filter housing.

- Install the engine compartment trim.

- Fill the engine oil.

- Fill with coolant => [ Filling ] Procedures.