Upper Timing Cover (G2523509): Installation

The following step(s) applies to: 

All vehicles 

1. CAUTION: Make sure that the mating faces are clean and free of foreign material.

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   Apply a 3 mm diameter bead of RTV sealant, to the area shown.

   Refer to: SPECIFICATIONS .

2. CAUTION: Make sure that the mating faces are clean and free of foreign material.

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   Install the upper timing cover gasket. Make sure that the gasket is installed correctly on to the locating dowels.

   Renew Part: Timing chain cover gasket Quantity: 1 . 

3. Fig 1: Upper Timing Cover Tightening Sequence

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   • Install the upper timing cover.
   • Install and tighten the 12 bolts in the sequence shown in the illustration.

     Torque 

     Tighten: 14 Nm 

     Loosen: 180° 

     Tighten: 14 Nm 

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   Lubricate the VCT  solenoid bores with clean engine oil.

   Refer to: SPECIFICATIONS .

5. CAUTION: Make sure that the area around the component is clean and free of foreign material.

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   • Install 2 new VCT  solenoid O-ring seals.

     Renew Part: Variable Camshaft Timing (VCT) solenoid O-ring seals Quantity: 2 . 

   • Install the 2 VCT  solenoids.
   • Install and tighten the 4 bolts.

     Torque  : 9 Nm 

6. Install the NVH  material.

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   • Install the fuel injector pump bracket.
   • Secure the 3 clips.
   • Connect the electrical connector.
   • Install and tighten the 4 bolts.

     Torque  : 12 Nm 

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   • Reposition the exhaust pressure sensor to the original location.
   • Install and tighten the 3 bolts.

     Torque  : 10 Nm 

   • Reposition the 2 coolant hoses to the original location.
   • Secure the coolant hose clip.

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   • Secure the 5 wiring harness clips.
   • Connect the 2 electrical connectors to the 2 VCT  solenoids.
   • Connect the exhaust pressure sensor.
   • Secure the 2 wiring harness clips to the pipe.

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    • Install the coolant separator bracket.
    • Install and tighten the 2 bolts.

      Torque  : 10 Nm 

    • Secure the clip.

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    • Secure the 3 clips.
    • Secure the EPR  lever to the bracket.

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    • Install the coolant separator.
    • Install and tighten the 2 bolts.

      Torque  : 12 Nm 

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    • Install the 2 coolant hoses to the underside of the coolant separator.
    • Secure the 2 coolant hose clamps and remove the 2 hoses.
    • Secure the bleed line connection.
14. Install the left side secondary bulkhead outer panel.

    Refer to: SECONDARY BULKHEAD LEFT OUTER PANEL .

15. Install the right side secondary bulkhead inner panel.

    Refer to: SECONDARY BULKHEAD RIGHT INNER PANEL - INGENIUM I4 2.0L PETROL .

16. Install the hood.

    Refer to: HOOD .

17. Vacuum fill the engine cooling system.

    Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING .

18. Connect the 12V system.

    Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .

    The following step(s) applies to: 

    Plug in hybrid electric vehicles only 

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    Power Up the HV  system. Only technicians qualified to EVAP  level are allowed to perform this procedure. It is mandated that all technicians involved with the steps in this procedure have read and understood the EV  Safety Rules.

    Refer to: PHEV POWER DOWN/UP - COMPLETE VEHICLE - PATHFINDER .