The battle rages on..
I wasn't confident in the 'flattened' seal of the cabin air filter tray, i so removed it again and used suitably sized bitumen tape to re-seal it:
A few days later a large box from Auto doc arrived. It contains a whole timing belt kit from INA, as well as cam cover gasket service items.
I wasted no time and started with the top.
Cam cover off, all cleaned, replaced the chain tensioner sliders, removed the gauze filter and re-assembled it using new gaskets of course:
The long life oil service intervals really aren't doing this engine any good...:
Cam cover was leaking quite bad causing misfires:
Next it was time for the timing belt itself. I knew I'd have to drain all the coolant out of the engine, so i bought a set of metal coolant pipes:
They were quite cheap and needed cleaning up with a dremel and a burr bit. I also lapped the coolant flange to make sure it really sealed well:
I then fitted all the pipes, they went in without any trouble:
Next was the timing belt, I followed instructions from Elsa step by step. The hardest bit for me by far was removing the engine mount. It was an absolute pain of a job.
The timing belt itself was dated 2009, and the hydraulic tensioner was held on with just one finger tight bolt...
New belt, tensioner, guide pulley and water pump in:
I also replaced the lower crank seal, a 35mm socket was perfect to hammer it in:
I also used new shiny new bolts on the bottom pulley:
As you can see above the control arms have seen a better day and will need doing too, for now they are ok - they don't knock or have any play.
Aux belt tensioner was replaced too:
I also checked the wear on alternator regulator brushes and given that the car has covered 109k id say they are 50% gone. Keep in mind this car has an automatic gearbox and heated seats..:
New vs old water pumps: