[Previous][Next]
REMOVAL AND INSTALLATION
 
 
Removal steps
1.Breather hose
2.PCV hose
3.PCV valve
4.O-ring
5.Oil filler cap
6.O-ring
7.Engine oil drain plug
8.Engine oil drain plug gasket
9.Engine oil filter
10.Engine oil cooler
11.Engine oil cooler gasket
12.Engine oil filter bracket
13.Engine oil filter gasket
14.Rocker cover
15.Rocker cover gasket
16.A/C compressor bracket
17.Engine oil pan
18.Stiffener
19.Crankshaft front oil seal
20.Gasket
21.Gasket
22.Timing chain case assembly
 
 
REMOVAL SERVICE POINTS
 
 
<<A>> ENGINE OIL FILTER REMOVAL
1. Use special tool oil filter wrench (MB991396) or commercially-available tool to remove the engine oil filter.
 

 
 
<<B>> ENGINE OIL PAN REMOVAL
1. Remove engine oil pan tightening bolts.
cautionLightly tap the engine oil pan FIPG cutter to drive in, taking care not to damage the ladder frame and engine oil pan sealed area.
2. Lightly tap special tool oil pan FIPG cutter (MD998727) to drive in the illustrated groove of the engine oil pan and ladder frame.
3. Lightly tap and slide special tool oil pan FIPG cutter (MD998727) to remove the oil pan.
 

 
 
<<C>> TIMING CHAIN CASE ASSEMBLY REMOVAL
1. Remove the timing chain case assembly bolt, and then remove the timing chain case assembly from the cylinder head and cylinder block.
2. If the sealant cannot be peeled off easily, insert a wooden hammer shank into the timing chain case assembly inside as shown in the figure, pry slightly, and remove the timing chain case assembly from the cylinder head and cylinder block.
 
 
 
 
INSTALLATION SERVICE POINTS
 
 
>>A<< TIMING CHAIN CASE ASSEMBLY INSTALLATION
caution
  • Completely remove all the old sealant, which might be remaining in the installation hole, the O-ring groove or among the components such as the cylinder head gasket.
  • 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.
1. Completely remove sealant adhering to the timing chain case assembly, cylinder block and cylinder head.
2. Apply a layer of sealant 2.5 ± 0.5 mm (0.098 ± 0.019 inch) thick to locations A and B, and a layer 3.5 ± 0.5 mm (0.137 ± 0.019 inch) thick to locations C and D on the timing chain case assembly as shown in the figure.
Specified sealant: ThreeBond 1217G or equivalent
3. Degrease the surface where the sealant is applied and the contact surface between the cylinder block and the cylinder head.
4. The engine oil staying at the cylinder gasket oozes to the 3-plane contact surface described in Step 2 and 3. Swiftly apply the sealant to this area after degreasing.
Specified sealant: ThreeBond 1217G or equivalent
noteInstall the timing chain case assembly immediately after applying sealant.
cautionIf the sealant contacts any other part during installation of the timing chain case assembly, apply sealant again before installing the timing chain case assembly.
5. Install the timing chain case assembly to the cylinder block and cylinder head so that the sealant does not contact other parts.
cautionAfter the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
6. Tighten timing chain case assembly mounting bolts to the specified torque.
Tightening torque:
  • A: 24 ± 4 N·m (18 ± 2 ft-lb)
  • B: 24 ± 4 N·m (18 ± 2 ft-lb)
  • C: 24 ± 4 N·m (18 ± 2 ft-lb)
  • D: 10 ± 2 N·m (89 ± 17 in-lb)
  • E: 10 ± 2 N·m (89 ± 17 in-lb)
  • F: 12 ± 1 N·m (107 ± 8 in-lb)
  • G: 35 ± 5 N·m (26 ± 3 ft-lb)
  • H: 35 ± 5 N·m (26 ± 3 ft-lb)
 
 
 
>>B<< CRANKSHAFT FRONT OIL SEAL INSTALLATION
cautionThe front oil seal must not be a strong press fit. The strong press fit can possibly cause the oil leakage, damaging the crankshaft front oil seal.
1. Apply a small amount of engine oil to the entire inner diameter of the crankshaft front oil seal lip.
2. Use special tool bush remover and installer base (MB991448) in order to press-fit the crankshaft front oil seal into the timing chain case as shown in the illustration.
 
 
 
>>C<< ENGINE OIL PAN INSTALLATION
cautionSufficiently 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.
1. Remove all the traces of sealant adhering to the engine oil pan and cylinder block assembly using a remover or others. Then, degrease them.
2. Apply the sealant 2.5 ± 0.5 mm (0.098 ± 0.019 inch)  in diameter to the engine oil pan as shown in the illustration.
Specified sealant: ThreeBond 1217G or equivalent
noteInstall the engine oil pan immediately after applying sealant.
cautionAfter 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.
3. Tighten the engine oil pan mounting bolts to the specified torque.
Tightening torque:
  • M6: 10 ± 2 N·m (89 ± 17 in-lb)
  • M8: 31 ± 2 N·m (23 ± 1 ft-lb)
 
 
 
>>D<< ROCKER COVER INSTALLATION
cautionSufficiently 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.
1. Completely remove sealant adhering to the rocker cover, timing chain case assembly and cylinder head, and degrease the surface.
2. Use a minimum amount of the sealant appropriately. Make sure that the sealant does not stick out from the application area.
Apply the sealant 4 mm (0.157 inch) in diameter.
Specified sealant: ThreeBond 1217G or equivalent
noteInstall the cylinder head cover assembly immediately after the application of sealant.
3. Tighten the rocker cover mounting bolts to the specified torque in the order shown in the illustration.
Tightening torque: 3.0 ± 1.0 N·m (27 ± 8 in-lb)
cautionAfter 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.
4. Tighten again the rocker cover mounting bolts to the specified torque in the order shown in the illustration.
Tightening torque: 5.5 ± 0.5 N·m (49 ± 4 in-lb)
 
 
 
>>E<< ENGINE OIL FILTER INSTALLATION
1. Clean the engine oil filter installing surface on the ladder frame side.
2. Apply a small amount of engine oil to the new engine oil filter O-ring.
3. Tighten the engine oil filter until the O-ring contacts with the installation surface.
4. In the same manner as removal, use special tool oil filter wrench (MB991396) or commercially-available tool to tighten the engine oil filter to the specified torque.
Tightening torque: Approximately 1 turn [14 ± 2 N·m (124 ± 17 in-lb)]