8.1. Timing chain cover installation details:
1 - Rear crankshaft oil seal;
2, 14 - Centering bushings, 2 pcs.;
3, 5, 7, 13 - Bolts subject to replacement, tightened in several approaches, with a final force of 9 Nm;
4 - Left upper timing chain cover;
6, 12 - Gasket, subject to replacement;
8 - Bolt, 9 Nm;
9 - Sealing cover;
10 - O-ring, must be replaced;
11 - Right upper timing chain cover;
15 - Sealing element;
16 - Lower timing chain cover;
17 - Cover fastening bolts 16.
2. Remove the drive disc (see Section 7) and the rear right coolant pipe (see Chapter 3), and on CASA/CASB engines, additionally remove the rear left coolant pipe.
3. Remove the turbocharger (see Chapter 4).
4. Remove the left and right intermediate pipes of the exhaust system (see Chapter 4).
5. Drain the engine oil (see Section 6 of Chapter 1).
6. Remove the bolts (1-4 in the illustrations) and remove the lids.
8.6a. Upper left timing chain cover mounting bolts.
8.6b. Upper right timing chain cover mounting bolts.
7. On CASA/CASB engines, remove the bolt (arrow in the illustration) and remove the lower section of the return oil pipe (1) from the cylinder block.
8.7. Fastening the lower section of the return oil pipe to the cylinder block (cASA/CASB engines).
8. Remove the bolts (1-9 in the illustration) and remove the lower timing chain cover.
8.8. Lower timing chain cover mounting bolts.
Remove the rear crankshaft oil seal from it (see Section 7).
9. Using a plastic drill brush attachment, remove old sealant from the cover grooves and from the mating surfaces of the cover/cylinder head/cylinder block. At the same time, do not allow dirt to enter the lubrication system. Clean mating surfaces from oil and grease.
Note: After subsequent application of sealant, the lid must be installed within 5 minutes.
10. Install the sealing elements into the lower chain cover (2 and 5 in the illustration) and apply beads of sealant into the grooves (1 and 4).
8.10. Lower timing chain cover seal parts.
The sealant should completely fill the grooves and protrude 1.5-2.0 mm. Apply 1.5-2.0 mm diameter beads of sealant around holes (3 and 6). Make sure there are two centering bushings for the lower chain cover in the cylinder block. Install the cover and tighten its fasteners in the following order. Tighten all bolts first (1...9 in illustration 8.8) with a force of 5 Nm in a diagonal order, starting from the inside and moving outwards. Then, also in a diagonal order, tighten bolts (1...7) to 9 Nm. Finally, tighten bolts (8 and 9) to 23 Nm.
11. Apply a bead of sealant into the groove (1 in illustration 8.11a) left upper chain cover.
8.11a. Places to apply sealant to the left upper timing chain cover.
The sealant should completely fill the groove and protrude from it by 1.5-2.0 mm. Place the gasket (2). Apply 3 mm diameter beads of sealant to the joints of the left cylinder head and the lower timing chain cover (see illustration 8.11b), install the left upper chain cover and tighten its bolts in the following order.
8.11b. Places where sealant is applied to the joint of the left cylinder head.
Tighten the bolt first (1 in illustration 8.11c) - with a force of 3 Nm, and then tighten the bolts in sequence (2-1-3) with a force of 9 Nm.
8.11s. Left upper timing chain cover bolt tightening sequence.
Note: Tighten the bolts (3) in a diagonal order.
12. Install the right upper timing chain cover in the same manner.
13. Install the new rear crankshaft oil seal and drive plate (see Section 7).
14. Install the lower section of the return oil line, intermediate outlet pipes and turbocharger.
15. Install the coolant pipes, add engine oil and check the coolant level (see Chapter 1).
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