Attention! When installing the bottom cover, sealant and a new O-ring for the coolant pipe must be used. It is also advisable to replace the front crankshaft O-ring.
Removing
Unscrewing the bolts and bracket from the drive chain cover
After loosening the central bolt (A) auxiliary drive belt tensioner unscrew the three bolts (IN) and turn the bracket (1) from the drive chain cover.
Elements of fastening of an arm of the fan of a radiator and the gauge of an angle of rotation of a cranked shaft
1 - radiator fan bracket; 2 - bolts; 3 - crankshaft rotation angle sensor; 4 - nut
Arrangement of bolts of fastening of the oil pallet to the bottom cover of a driving chain
Removing the bottom drive chain cover
1. Remove the ground wire from the battery.
2. Open the hood and place it in a vertical position.
3. Remove the engine mudguard.
4. Remove the air filter.
5. Remove the fan impeller and hydraulic clutch.
6. Remove the bolt securing the air intake tube to the front body panel.
7. Remove the auxiliary drive belt.
8. Unscrew the bolts and remove the auxiliary drive belt pulleys.
9. Remove the crankshaft pulley/vibration damper and hub.
10. Remove the top drive chain cover.
11. Loosen the center bolt of the auxiliary drive belt tensioner, then unscrew the three bolts and rotate the bracket away from the drive chain cover (see fig. Unscrewing the bolts and bracket from the drive chain cover).
12. Remove the two bolts securing the power steering pump to the bracket and rotate the pump away from the engine.
13. If present, remove the air pump and move it to the side without disconnecting the hoses from it.
14. Unscrew the bolts and remove the radiator fan bracket (see fig. Elements of fastening of an arm of the fan of a radiator and the gauge of an angle of rotation of a cranked shaft).
15. Unscrew the nut and remove the crankshaft angle sensor from the bracket on the timing chain cover. Release the sensor wiring from the mounting brackets and move the sensor to the side.
16. Disconnect the electrical wires from the generator.
17. Unscrew the four bolts securing the generator bracket to the engine and remove the generator together with the bracket.
18. Working under the vehicle, remove the bolts securing the oil pan to the lower drive chain cover (see fig. Arrangement of bolts of fastening of the oil pallet to the bottom cover of a driving chain). Note the location of the bolts as they are different sizes.
19. Unscrew the remaining bolts securing the lower drive chain cover, noting their location, as bolts of different sizes are used.
20. Remove the lower drive chain cover (see fig. Removing the bottom drive chain cover).
Attention! When removing the lower drive chain cover, be careful not to damage the oil pan gasket.
Installation
Applying sealant to the mating surfaces of the cylinder block and lower drive chain cover
After applying sealant to the mating surfaces of the cylinder block and the lower drive chain cover (A) check that the sealant does not get into the channels of the oil supply chamber to the drive chain tensioner (IN).
Replacing the sealing ring in the hole for the bottom bolt of the radiator fan bracket
1. Clean the mating surfaces of the lower drive chain cover, engine block and upper drive chain cover.
2. Check the condition of the oil pan gasket. If the gasket is damaged, replace it.
3. Clean the o-ring seat.
4. Install a new o-ring into the cap seat.
5. In order not to damage the working edges of the crankshaft sealing ring when installing the lower cover of the drive chain, wrap the front end of the crankshaft with adhesive tape.
6. Apply a thin layer of sealant to the mating surfaces of the cylinder block and timing chain cover. Be careful not to get sealant into the oil supply chamber to the drive chain tensioner in the cover or into the oil passages (see fig. Applying sealant to the mating surfaces of the cylinder block and lower drive chain cover).
7. Lubricate the sealing lips of the crankshaft seal with clean engine oil and install the lower timing chain cover on the cylinder block.
8. Screw in the bolts securing the oil pan to the drive chain cover and tighten them to the required torque.
9. Screw in the remaining bolts of the drive chain cover and tighten them to the required torque.
10. Replace the o-ring installed in the bottom bolt hole of the radiator fan bracket in the timing chain cover (see fig. Replacing the sealing ring in the hole for the bottom bolt of the radiator fan bracket).
11. Remove the adhesive tape from the front end of the crankshaft.
12. Install the generator and connect the wires to it.
13. Install the crankshaft angle sensor to the bracket on the timing chain cover and secure it with the nut.
Attention! When installing a new lower timing chain cover, check and, if necessary, adjust the position of the crank angle sensor.
14. Install the radiator fan bracket and secure it with the bolts.
15. Install an air pump if available.
16. Reinstall the power steering pump and secure with bolts.
17. Apply sealant on both sides of the timing chain cover bolt holes in the auxiliary timing belt tensioner bracket.
18. Rotate the auxiliary drive belt tensioner bracket into place and secure with bolts.
19. Install the upper drive chain cover.
20. Install the crankshaft pulley/vibration damper and hub.
21. Install and bolt the auxiliary drive belt pulleys.
22. Install the auxiliary drive belt.
23. Install and bolt the air intake tube.
24. Install the hydraulic clutch and radiator fan impeller.
25. Install the air filter.
26. Install the lower engine mudguard.
27. Fill the cooling system with coolant.
28. Check the level and, if necessary, add engine oil to the engine.