REMOVAL AND INSTALLATION







Removal steps

>>F<<
1.
Peak torque limiter
<<A>>
>>E<<
2.
Flywheel bolt


3.
Flywheel

>>D<<
4.
Rear oil seal
<<B>>
>>C<<
5.
Balancer shaft chain tensioner


6.
Balancer tensioner lever


7.
Balancer chain guide
<<B>>
>>B<<
8.
Balancer shaft and oil pump module
<<B>>
>>B<<
9.
Balancer chain
<<B>>
>>B<<
10.
Crankshaft sprocket
<<C>>
>>A<<
11.
Ladder frame

REMOVAL SERVICE POINTS



<<A>> FLYWHEEL BOLT REMOVAL



1.Use special tool Flywheel stopper (MD998781) to secure the flywheel.
2.Remove the flywheel bolts.

<<B>> BALANCER CHAIN TENSIONER/CRANKSHAFT SPROCKET/BALANCER CHAIN/BALANCER SHAFT AND OIL PUMP MODULE REMOVAL


caution Reliably secure the plunger of the chain tensioner with hard wire to prevent it from jumping out of the main body.

1.Push in the balancer tensioner lever by hand and push in the plunger of the balancer chain tensioner until it contacts the bottom. Then, insert hard wire (piano wire, etc.) of Φ1.5 or hexagonal bar wrench (1.5 mm) into the plunger fixing hole to secure.
2.Remove the balancer chain tensioner.

3.
caution The balancer shaft and oil pump module must not be disassembled because of assembly warranty.
Remove the crankshaft sprocket, balancer chain and balancer shaft and oil pump module as a unit.

<<C>> LADDER FRAME REMOVAL



1.Pry the illustrated position with a screwdriver or tap the boss with a hammer.

2.If the ladder frame does not come off, insert a flatblade screwdriver into the gap between the ladder frame and bearing cap as shown in the illustration and lightly pry it to remove the ladder frame.

INSTALLATION SERVICE POINTS



>>A<< LADDER FRAME INSTALLATION


1.
caution Be sure to remove liquid gasket that has entered mounting holes.
Completely remove liquid gasket adhering to the cylinder block and ladder frame.
2.
caution
  • Sufficiently check that there is no residual oil on the place where degreasing is performed.
  • If fingerprints are left, do not touch it with bare hands after the degreasing, since the oils from your fingers will harm the seal ability.
Degrease the surface where the liquid gasket is applied and the contact surface between the cylinder block and ladder frame.

3.Squeeze liquid gasket of Φ2.5 ± 0.5 mm in thickness and apply it to the illustrated position of the ladder frame.
Specified sealant:
    ThreeBond 1227D or equivalent

4.Tighten the ladder frame to the specified torque of 24 ± 2 N·m in the order shown in the illustration.

>>B<< CRANKSHAFT SPROCKET/BALANCER CHAIN/BALANCER SHAFT AND OIL PUMP MODULE INSTALLATION



When the new balancer shaft and oil pump module is installed, supply oil to the oil pump and the balancer shaft bearing in the balancer shaft and oil pump module using the following procedures.

  1. Clean the inside of the removed oil pan. Put the balancer shaft and oil pump module carefully into the oil pan so that the oil inlet can be upward.
  2. Pour the engine oil so that the two-third of the balancer shaft and oil pump module can be immersed.
  3. Also, pour approximate 50 cc of engine oil from the oil inlet.
  4. By giving four clockwise rotations or more to the balancer shaft sprocket, the oil is supplied to the oil pump and the balancer shaft bearing.

1.Wipe the dirt on the crankshaft sprocket and the crankshaft using a rag, and then remove the grease from the portion shown in the illustration.
note Remove grease to prevent a drop in the coefficient of friction of the pressing portion caused by adhesion of oil.

2.Align the timing mark of the balancer shaft sprocket with that of the balancer shaft and oil pump module.
3.Insert a hexagonal bar wrench (3 mm) as illustrated to prevent the balancer shaft sprocket from moving.
4.Loop the balancer chain, aligning its link plate (blue) with the timing mark.
5.Install the crankshaft sprocket on the crankshaft.
note Do not push in the crankshaft sprocket to the normal position. Push it in only up to the tip of the crankshaft.


6.While slanting the balancer shaft and oil pump module, align the link plate (blue) of another balancer chain with the timing mark of the crankshaft sprocket to loop. Gradually push in the crankshaft sprocket and fit it into the key groove of the crankshaft. Then, install the balancer shaft and oil pump module on the ladder frame.
note Make sure that the balancer shaft module is completely intimate contact with the ladder frame.
note Make sure that the key groove of the crankshaft is aligned with the contact surface of the cylinder block and ladder frame as shown in the illustration.

7.Apply an appropriate and minimum amount of engine oil to the screw thread of the balancer shaft and oil pump module bolt.

8.Tighten bolts to the specified torque of 20 N·m according to the assembly order in the illustration, retighten them to 44 N·m, and then completely loosen them.

9.After tightening them to the specified torque of 20 N·m again, use special tool Angle gauge (MB991614) to tighten them up to 135°.
10.Pull out the hexagonal bar wrench from the balancer shaft sprocket.

11.Make sure that the respective timing mark is aligned with each other as illustrated.
12.Install the balancer tensioner lever and balancer chain guide.

>>C<< BALANCER CHAIN TENSIONER INSTALLATION



1.Attach the balancer chain tensioner to the ladder frame.
2.
caution Install the balancer chain tensioner precisely in place after installing the balancer tensioner lever and balancer chain guide to prevent the plunger of the balancer chain tensioner from jumping out.
Remove the hard wire (piano wire, etc.) of Φ1.5 or hexagonal bar wrench (1.5 mm) from the balancer chain tensioner. This enables the plunger of the balancer chain tensioner to push the balancer tensioner lever to keep the balancer chain tight.

>>D<< REAR OIL SEAL INSTALLATION



caution Do not apply oil to the circumference of the oil seal and oil seal pressing hole on the cylinder block side to prevent teeth from pulling out.
After applying a small amount of engine oil to the oil seal lip, use special tool Rear oil seal installer (MD998718) to press fit the oil seal.

>>E<< FLYWHEEL BOLT INSTALLATION


1.Clean off sealant and oil of thread of crankshaft and flywheel bolts.

2.Use special tool Flywheel stopper (MD998781) to secure the flywheel.

3.Apply engine oil to thread of crankshaft and bolt seat area of flywheel.
4.Apply the sealant to the thread of flywheel bolts.
Specified sealant:
    ThreeBond 1324 or equivalent

5.Tighten flywheel bolts to temporary torque of 40 N·m in the order shown to illustration.
6.Tighten flywheel bolts to specified torque of 130 N·m in the order shown in the illustration.

>>F<< PEAK TORQUE LIMITER INSTALLATION



1.Tighten the six bolts securing the peak torque limiter by hand.
2.Tighten the bolts securing the peak torque limiter in the sequence shown to 27 ± 1 N·m.