Lower Timing Chain Cover

Lower Timing Chain Cover

Special tools, testers and auxiliary items required

• Hand drill with plastic brush attachment

• Protective goggles

• Sealant, refer to the Parts Catalog

Removing

• The transmission is removed.

• Engine oil drained.

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

- Remove the drive plate. Refer to => [ 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.

- Disconnect the starter electrical connector - 3 - by sliding the retainer back and pressing the release down.






- Remove the electrical wire nut - 2 - and starter.

• Ignore - 1 and 4 -.

- Remove the bolts - arrows -.






- Loosen and remove the bolts - 1 through 10 - 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.

• 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 goggles.

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






- Clean any oil or grease off the sealing surfaces.

- 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 any oil and grease off the cylinder head seals.

• 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.

• Draw through the sealant bead - 2 - as illustrated, even though the groove is intermittent.

• Timing chain cover must be installed within 5 minutes of applying sealant.

- Insert the seals - arrows - in 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 transmission-side crankshaft shaft seal. Refer to => [ Crankshaft Seal ] Service and Repair.

- Install the starter.

- 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.

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

- Fill engine with oil and check oil level.