Installing Lower Chain Housing Cover (R4)

Information 

The lower chain housing cover must be replaced.

1. Remove residual sealant on the cylinder block.
2. Clean sealing faces to remove any oil and grease.
3. Check that the dowel pins for the centering device -1-  are fitted correctly.

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   Centering device for chain housing cover

4. Cut off the nozzle on the sealant tube at the front marking. (The nozzle diameter is approx. 3 mm).

   Information 

   • Make sure that the bead of sealant you apply is not thicker than the prescribed thickness. Excess sealant can block the lubrication system. 
   • The chain housing covers must be installed within 5 minutes of applying the sealant. 
5. Apply sealant to the sealing face -1-  and edges -2-  of the new  chain housing cover.

   Sealant bead thickness: 2...3 mm

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   Sealant on lower chain housing cover

6. Install new  chain housing cover -16-  .
   1. 6.1  Position chain housing cover -16-  and fit new  screws -1 to 15-  .
   2. 6.2  Tighten screws in the sequence -1 to 15-  .

      Initial tightening 8 Nm (6 ftlb.) 

      Final tightening + 45° 

   Fig 1: Lower Chain Housing Cover Screws Tightening Sequence

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   Lower chain housing cover

7. Install oil pressure switch -1-  .
   1. 7.1  Coat new seal with engine oil and insert it.
   2. 7.2  Fit and tighten new screw -3-  .

      Initial tightening 4 Nm (3 ftlb.) 

      Final tightening + 90° 

   3. 7.3  Connect and lock cable plug -2-  .

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   Oil pressure switch

8. Install guide tube for oil dipstick -1-  .
   1. 8.1  Install new O-ring -5-  on guide tube.
   2. 8.2  Fit guide tube for oil dipstick -1-  into the lower chain housing cover.
   3. 8.3  Clip guide tube for oil dipstick into the upper chain housing cover -4-  .
   4. 8.4  Secure coolant pipe -2-  .
      1. 8.4.1  Fit and tighten screws -3-  .

         > Tightening - torque 9 Nm (6.5 ftlb.) 

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   Guide tube for oil dipstick

9. Connect and lock cable plug -2-  .

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   Oil-pressure sender on oil filter bracket

10. Unscrew screw for pulley and remove T10368 - thrust piece-1-  .

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    Thrust piece on crankshaft