REMOVAL AND INSTALLATION



Pre-removal Operation
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Upper Cover Removal (Refer to GROUP 13D - Fuel Injector ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Rocker Cover Assembly Removal (Refer to ).
  • Exhaust Centre Pipe and Backbone Brace Removal (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).
  • Headlamp Support Panel Cover Removal (Refer to GROUP 51 - Front Bumper Assembly and Radiator Grille Assembly ).
  • Crankshaft Pulley Removal (Refer to ).

Post-installation Operation
  • Crankshaft Pulley Installation (Refer to ).
  • Exhaust Centre Pipe and Backbone Brace Installation (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).
  • Rocker Cover Assembly Installation (Refer to ).
  • Headlamp Support Panel Cover Installation (Refer to GROUP 51 - Front Bumper Assembly and Radiator Grille Assembly ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Upper Cover Installation (Refer to GROUP 13D - Fuel Injector ).
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 - Under Cover ).





Removal steps


·
Intercooler inlet air pipe B connection (Refer to GROUP 15 - Intercooler )


·
Engine oil pan strainer (Refer to )


·
Water pump pulley (Refer to GROUP 14A - Water Pump )


1.
Cylinder block engine front mounting bracket

>>B<<
2.
Oil pump drive shaft
<<A>>

·
Engine mounting bracket (Refer to GROUP 32 - Engine Mounting ).
<<B>>
>>A<<
3.
Timing chain case assembly

>>A<<
4.
O-ring


·
Crankshaft front oil seal (Refer to )

REMOVAL SERVICE POINTS



<<A>> ENGINE AND TRANSMISSION ASSEMBLY HOLDING


Install a special tool for holding the engine and transmission assembly.

1.Install the engine hanger right (MD016967) to the cylinder head.

2.Install the special tool engine hanger plate (MB991956) to the cylinder head.


3.<When special tool engine hanger (MB991928) is used>
(1) Assemble special tool engine hanger (MB991928). (Set the following parts on the base hanger.)

  • Slide bracket (HI)
  • Joint x 2 (50) (MB991929)
  • Joint x 2 (90) (MB991930)
  • Joint x 2 (140) (MB991931)
  • Foot x 2 (standard) (MB991932)
  • Foot x 2 (short) (MB991933)
(2) Set the foot of the special tool as shown in the figure.
note Slide the slide bracket (HI) to adjust the engine hanger balance.
(3) Mount special tool hanger (MB991527) to the engine hanger, and set it to special tool MB991928 to support the engine and transmission assembly.

4.<When special tool engine hanger (MB991895) is used>
(1) Set the foot of special tool engine hanger (MB991895) as shown in the figure.
note Slide the foot to adjust the engine hanger balance.
(2) Mount special tool hanger (MB991527) to the engine hanger, and set it to special tool MB991895 to support the engine and transmission assembly.

<<B>> TIMING CHAIN CASE ASSEMBLY REMOVAL



Remove the timing chain case assembly mounting bolts, then screw in the M6 x 1.0 bolt to the area of the timing chain case assembly shown in the figure, and then remove the timing chain case assembly from the cylinder head and cylinder block.

INSTALLATION SERVICE POINTS



>>A<< O-RING/TIMING CHAIN CASE ASSEMBLY INSTALLATION


1.
caution
  • Be sure to remove the sealant remaining in the mounting hole, O-ring groove, and gap between parts.
  • After degreasing with degreasing agent, check that there is no oil on the surface where the sealant is applied.
  • After degreasing with degreasing agent, never touch the degreased area with fingers.
Remove sealant from the timing chain case assembly and the timing chain case assembly mounting surface of the cylinder block and the cylinder head, and degrease the surface where the sealant is applied.
2.Remove all the sealant adhering to the gasket between the cylinder head and cylinder block (three-surface aligned part.) Then, degrease the surfaces.
3.As for the three-surface aligned part that is indicated in Step 2 above, the engine oil oozes from the cylinder head gasket. Thus, quickly apply the sealant to it after degreasing.

4.Apply a bead of the sealant to the timing chain case assembly mounting surface. The bead diameter should be 2.5 ± 0.5 mm. Overlap the part "A" with the diameter of 2.5 ± 0.5 mm as shown in the figure, and apply the sealant.
Specified sealant: ThreeBond 1217G or equivalent
5.
caution
  • When installing the timing chain case assembly, make sure that the O-ring is fitted into the groove securely.
  • If the sealant contacts any other part during installation of the timing chain case assembly, apply sealant again before installing the timing chain case assembly.
  • After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
Install the timing chain case assembly to the cylinder block and cylinder head so that the sealant does not contact other parts.
note Install the timing chain case assembly immediately after applying sealant.

6.Install the timing chain case assembly mounting bolts to the installation positions shown in the figure, and tighten them to the specified torque.
Bolt (Symbol)
Diameter × length mm
A
6 × 16
B
6 × 20
Tightening torque: 11 ± 3 N·m

>>B<< OIL PUMP DRIVE SHAFT INSTALLATION



1.After wiping off the dirt on the oil pump drive shaft as shown in the figure using a rag, degrease the area.
note Degrease them to prevent drop in the friction coefficient of the pressed area, which is caused by oil adhesion.
2.Install the oil pump drive shaft with the chamfered side facing the crankshaft side.