Cover - Timing Gear - Lower

12.65.43.01 Cover - timing gear - lower
Remove
1. Remove timing gear upper covers.
2. Remove crankshaft front oil seal.





3. Remove 2 bolts securing ancillary drive belt tensioner to lower timing gear cover.
4. Remove dust cap from ancillary drive belt tensioner idler pulley and remove Torx bolt securing ancillary drive belt tensioner idler pulley.
5. Remove ancillary drive belt tensioner assembly.





6. Remove 2 bolts securing A/C compressor drive belt tensioner.
7. Remove remaining bolt securing A/C compressor drive belt tensioner and remove tensioner.





8. Remove nut and disconnect battery cable from alternator.
9. Release battery cable from lower timing gear cover.





10. Remove 6 alternator securing bolts and alternator harness securing clip.
11. Release and remove alternator from engine timing cover.
12. Discard alternator O-ring.





13. Remove 2 Allen bolts and 1 nut securing PAS pump and move aside.





14. Remove 6 bolts securing coolant pump
15. Support coolant rail pipes and remove coolant pump, remove and discard coolant pump O-rings.

Disassembly





1. Remove 6 bolts securing lower timing gear cover to upper sump.





2. Remove 15 bolts securing lower timing gear cover to cylinder block.

NOTE: Note position of all bolts as they are different lengths:
^ A = M8 x 75 mm
^ B = M6 x 40 mm
^ C = M6 x 85 mm
^ D = M6 x 80 mm
^ E = M8 x 90 mm
^ F = M6 x 60 mm
3. Remove lower timing gear cover.
4. Discard 3 lower timing gear cover gaskets.

Inspect
1. Clean timing gear cover and mating faces, clean dowels and dowel holes.

Reassembly





1. Apply sealant STC 50550 to areas illustrated.
2. Fit 3 new lower timing gear cover gaskets.
3. Fit lower timing gear cover.
4. Fit 15 bolts securing lower timing gear cover to cylinder block and initially tighten to 5 Nm (4 ft. lbs.).
5. Tighten 6 mm bolts securing lower timing gear cover to 10 Nm (7 ft. lbs.) and 8 mm bolts securing lower timing gear cover to 22 Nm (16 1 ft. lbs.).

CAUTION: Check torque of all bolts once they have been tightened down.

6. Fit 6 bolts securing lower timing gear cover to upper oil sump and tighten to 12 Nm (9 ft. lbs.).

Refit
1. Lubricate new O-rings and fit to sealing grooves in coolant pump.
2. Clean coolant pump housing and mating faces.
3. Fit new gasket to coolant pump, fit pump to engine and secure with bolts tighten bolts to 10 Nm (7 ft. lbs.).
4. Position PAS pump to mounting, fit Allen bolts and securing nut. Tighten Allen bolts to 10 Nm (7 ft. lbs.) and securing nut to 25 Nm (18 ft. lbs.).
5. Clean alternator and engine timing gear cover mating face.
6. Lubricate and fit Newell ring to alternator.
7. Fit alternator and tighten securing bolts.
8. Secure battery cable to lower timing gear cover.
9. Connect battery lead to alternator and tighten nut securing battery lead to alternator to 13 Nm (10 ft. lbs.).
10. Position A/C compressor drive belt tensioner and secure with bolt but do not tighten at this stage.
11. Fit 2 bolts securing A/C compressor drive belt tensioner to upper sump but do not tighten at this stage.
12. Fit ancillary dive belt tensioner assembly, fit Torx bolt securing ancillary drive belt tensioner idler pulley and tighten Torx bolt.
13. Fit dust cap to ancillary drive belt tensioner idler pulley.
14. Fit 2 bolts securing ancillary drive belt tensioner to timing gear cover but do not tighten at this stage.
15. Fit crankshaft front oil seal.
16. Fit timing gear upper covers.