Lower Timing Chain Cover

Lower Timing Chain Cover

Special tools, testers and auxiliary items required

• Hand drill with plastic brush attachment

• Protective eye wear

• Sealant, refer to the electronic parts catalog ETKA

Removing

• The transmission is removed.

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

- Remove the timing chain cover. Refer to => [ Left Timing Chain Cover ] Left Timing Chain Cover or => [ Right Timing Chain Cover ] Right Timing Chain Cover.

- Remove intake manifold.






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

- Remove the bolts - 1 - and - 2 - and move the left coolant pipe in the center to the side.






• Ignore - arrows -.

- Remove the bolts - arrows -.






- Loosen and remove the bolts - 1 through 12 - in a diagonal sequence.

- Carefully separate the timing chain guard lower section from the bond.

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

Installing






• Tightening specifications, refer to => [ Lower Timing Chain Cover, Tightening Specifications and Sequence ] Timing Chain Covers Overview.

Install in reverse order of removal. Note the following:

• Replace bolts which have been tightened to an additional torque.

- 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 contaminating lubricating system.

• Cover open parts of engine.

Risk of eye injury.

• Wear protective eye wear.

- Remove any sealant residue still on the timing chain guard lower section, cylinder block and cylinder head with a rotating plastic brush.






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

- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

- 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.

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).






- 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 9 - on the clean lower timing chain cover sealing surfaces as shown in the illustration.






• Thickness of sealant beads: 2.5 mm.

• The timing chains 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 Overview.

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

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

- Install the left coolant pipe in the center. Refer to => [ Left Coolant Pipe In Center ] Left Coolant Pipe In Center.

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

- Install intake manifold.

- Install the timing chain cover. Refer to => [ Left Timing Chain Cover ] Left Timing Chain Cover or => [ Right Timing Chain Cover ] Right Timing Chain Cover.

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