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.

• When installing, bring all cable ties back to same positions.








Risk of destroying electrical components.

• Complete the steps for disconnecting the battery.

- Turn off the ignition and remove the key.

- Disconnect the Ground (GND) cable - 2 - from the battery post.

- 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.

- Remove the generator.






- 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






• Replace seals, gaskets and O-rings.

- 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.

Danger of eye injury.

• Wear protective goggles.

- Remove the sealant residue on the cover for the timing chain, 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 the coat 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 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 - 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.






Install in reverse order of removal paying attention to the following:

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

- Install the starter and generator.

- 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.

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

- Fill the engine oil and check the level.