Lower Timing Chain Cover

Lower Timing Chain Cover

Special tools, testers and auxiliary items required

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Sealant, refer to the Parts Catalog.

Requirements:

• The engine is secured to the engine and transmission holder (VAS 6095). Refer to => [ Engine, Securing to ] Procedures.

Removing

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

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

- Remove the supercharger. Refer to => [ Supercharger ] Supercharger.

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

- Remove the upper coolant pipe. Refer to => [ Upper Coolant Pipe ] Upper Coolant Pipe.

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

- Disconnect the electrical connector - 3 - from the engine speed sensor.






• Ignore - 1 and 2 -.

- Remove the bolts - arrows -.






- Loosen and remove the bolts - 1 through 10 - in a diagonal sequence.

- Carefully remove the lower timing chain cover.

- Press the seal out of the lower timing chain cover.

Installing






• For tightening specifications, refer to => [ Lower Timing Chain Cover Bolt Tightening Sequence and Specification ] Timing Chain Covers Overview.

Installation is carried out in the reverse order while noting the following:

• Replace the bolts which have been tightened to a torque angle.

- Remove the upper right 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 the lubricating system.

• Cover open parts of the engine.

Risk of eye injury.

• Wear protective eyewear.

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






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

- Clean the transmission threaded holes in the cylinder block using a tap before installing the transmission.

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






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

The cylinder head gasket could be damaged.

• Only bend the ends of the cylinder head gaskets slightly, do not kink.

• A kinked cylinder head gasket must be replaced.

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






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

• Be sure to check the expiration date of the sealant.






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

- Lightly the lubricate the top and bottom of the cylinder head gasket sealing surfaces with lubricant by bending the gasket down slightly again - arrows -.






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

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






The lubrication system could be plugged with excess sealant.

• Do not apply the sealant beads 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 in the 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 - 3 - as illustrated, even though the groove is intermittent.

• The timing chain cover must be installed within 5 minutes after applying the 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 onto the sealing surface on the cylinder block and cylinder head.






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

- Tighten the bolts, refer to => [ Lower Timing Chain Cover Bolt Tightening Sequence and Specification ] Timing Chain Covers Overview.

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

- Install the crankshaft seal, refer to => [ Crankshaft Seal, Transmission Side ] Service and Repair.

- Install the starter.

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

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

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