Chain Cover

DISASSEMBLY

Bulkhead Connector:

1. If wiring or chain cover replacement is necessary, compress tabs on both sides of connector from inside of chain cover. Remove connector and wiring from chain cover.

CAUTION: Do not pull on wiring. Pull on connector.

Accumulator Piston Shafts:

2. Remove three accumulator piston shafts.

Accumulator Piston Service:

3. Using Lock Ring Pliers D81P-77O60-A or equivalent, remove three accumulator pistons. Remove seals and 0-ring from pistons.

CAUTION: Do not use any objects in piston shaft bore for removal or damage to bore may result.

Retaining Pin Collars:

4. Using side cutters, carefully remove bimetal retaining pin collars and remove bimetal and plate.

CAUTION: Use care not to damage machined case surfaces or bimetallic strips.

5. Pull retaining pins from cover, using Locknut Pin Remover T78P-3504-N.

Manual Valve Detent Spring:

6. Remove 8mm manual valve detent spring bolt and spring.


ASSEMBLY

Manual Valve Detent Spring:

1. Install manual valve detent spring and position tab in locator hole. Tighten bolt to 9-12 Nm (7-9 ft-lb).

Center Pin Max Height:

2. Start bimetal retaining pins in cover. Gently tap center pin to bottom of hole.

Bimetal Retaining Collars:

3. Place end of bimetal with hole over front retaining pin. Install bimetal retaining collars.

Bimetal Height Gauge:

4. Place Bimetal Height Gauge T86P-7O422-AR against retaining pin and under bimetal.
5. Gently tap retaining collar onto pin until it seats against tool edge.
6. Engage slotted end of bimetal under rear retaining pin and retaining collar and then repeat Steps 4 and 5 for slotted end of bimetal.

Plate Position:

7. Remove slotted end of bimetal from its pin. Position plate slotted ends onto rear and middle retaining pins. Install slotted end of bimetal under retaining collar.

Accumulator Piston Seals:

8. Install new seals and 0-ring on accumulator pistons.

NOTE: Lubricate seals and 0-ring with a light coating of petroleum jelly.

Accumulator Pistons Installation:

9. Install accumulator pistons into their proper cylinder.

CAUTION: Do not allow pistons to become misaligned in their bores. Seal and bore damage may result.

NOTE: New seals must be installed before installing pistons.

Accumulator Piston Shafts:

10. Install three accumulator piston shafts.
11. Install new 0-ring on internal harness connector, if removed.
12. Install new internal harness connector by pushing into bore from the outside until a "click" is heard.