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REMOVAL AND INSTALLATION
 
 
Pre-removal and Post-installation Operation
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal and Installation (Refer to GROUP 51 - Under Cover ).
  • Engine Oil Draining and Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Change ).
  • Cylinder Head Cover Assembly Removal and Installation (Refer to ).
  • Engine Oil Pan Removal and Installation (Refer to ).
Removal steps
<<A>>•Crankshaft pulley (Refer to ).
•Water pump pulley (Refer to GROUP 14A - Water Pump ).
<<B>>•Engine and front transaxle assembly holding
•Engine mounting bracket (Refer to GROUP 32 - Engine Mounting ).
1.Engine support bracket
2.Gasket
<<C>>>>D<<3.Timing chain case assembly
>>C<<4.Crankshaft front oil seal
<<D>>>>B<<5.Timing chain tensioner
6.Tensioner lever
>>A<<7.Valve timing chain
8.Timing chain guide

    Required Special Tools:
  • MB991454: Engine Hanger Balancer
  • MB991527: Hanger
  • MB991956: Engine Hanger Plate
  • MB991895: Engine Hanger
  • MB991448: Bush Remover and Installer Base
 
 
REMOVAL SERVICE POINTS
 
 
<<A>> CRANKSHAFT PULLEY REMOVAL
When removing the crankshaft pulley, slightly loosen the water pump pulley mounting bolts before removal of the water pump drive belt.

 
 
<<B>> ENGINE AND FRONT TRANSAXLE ASSEMBLY HOLDING
Install a special tool for holding the engine and front transaxle assembly.
1.
cautionPlace a rag between special tool MB991895 and the windshield to prevent the special tool MB991895 from interfering with the windshield.
Set the foot of special tool MB991895 as shown in the figure.
noteSlide the foot to adjust the engine hanger balance.
2. Install special tool MB991956 to the cylinder head, and set special tool MB991527 and the chains of special tool MB991454 to the engine assembly to hold the engine and front transaxle assembly.
 

 
 
<<C>> TIMING CHAIN CASE ASSEMBLY REMOVAL
1.
cautionIf the adhesive strength of sealant on the timing chain case assembly is so strong that the boss may be damaged by peeling off, do not peel it off forcibly.
After removing the timing chain case assembly mounting bolts, slightly pry the boss of the timing chain case assembly shown in the figure using a flat-tipped screwdriver, and 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.
 

 
 
<<D>> TIMING CHAIN TENSIONER REMOVAL
1. Temporarily install the crankshaft pulley to the crankshaft.
2.
cautionTurn the crankshaft clockwise.
Turn the crankshaft clockwise to align the sprocket timing marks as shown in the figure and set the cylinder No. 1 to the top dead center of compression.
noteAt this time, it is not necessary that the link plate (blue) of the valve timing chain always aligns with each sprocket timing mark.
3. Remove the crankshaft pulley installed temporarily.
4. Using a precision flat-tipped screwdriver, release the ratchet of timing chain tensioner.
5. Compress the plunger of timing chain tensioner and insert hard wire (such as the piano wire) of Φ1.5 mm (0.06 inch) or the L-shaped hexagon wrench [1.5 mm (0.06 inch)] to fix the plunger of the timing chain tensioner.
6. Remove the timing chain tensioner.
 
 

 
 
INSTALLATION SERVICE POINTS
 
 
>>A<< VALVE TIMING CHAIN INSTALLATION
1. Set the sprocket timing marks as shown in the figure.
2. Set the crankshaft keys as shown in the figure.
3. Align each sprocket timing chain timing mark with the link plate (blue) of valve timing chain to avoid slack of the valve timing chain tension side, and install the valve timing chain to the sprockets.
 

 
 
>>B<< TIMING CHAIN TENSIONER INSTALLATION
1. Check that the sprocket timing chain timing marks align with the link plates (blue) of the valve timing chain, and install the timing chain tensioner to the cylinder block.
2. Remove the hard wire or L-shaped hexagon wrench fixing the plunger of the timing chain tensioner to apply tension to the valve timing chain.
 

 
 
>>C<< CRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire inner diameter of the crankshaft front oil seal lip.
2.
cautionWhen installing the crankshaft front oil seal, be careful to avoid damage to the crankshaft front oil seal.
Use special tool MB991448 in order to press-fit the crankshaft front oil seal into the timing chain case as shown in the illustration.
 

 
 
>>D<< TIMING CHAIN CASE ASSEMBLY INSTALLATION
1.
cautionFollow the steps below to degrease the sealant application surface.
  • Before degreasing, make sure that the sealant application surface is free of dust, oil, or foreign materials.
  • Wipe the sealant application surface with a dry paper towel.
  • By using detergent for aluminum, degrease the sealant application surface by spray cleaning.
  • Wipe detergent thoroughly with a dry paper towel. Do not touch the sealant application surface with your fingers, as the fingerprints adhering to the sealant surface affect the sealing.
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 (0.10 ± 0.02 inch). Overlap the part "D" with the diameter of 4.5 ± 0.5 mm (0.18 ± 0.02 inch) or 2.5 ± 0.5 mm (0.10 ± 0.02 inch) as shown in the figure, and apply the sealant.
Specified sealant: Three bond 1217G or equivalent
5.
caution
  • 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.
noteInstall the timing chain case assembly immediately after applying sealant.
6. Insert the bolts to the timing chain case assembly as shown, and tighten them to the specified torque.
 
NameSymbolQuantitySize mm (D × L)
Flange boltA6M6 × 25
B6M8 × 30
BoltC1M6 × 25
noteD: Nominal diameter, L: Nominal length
  • Tightening torque:
    • A, C: 10 ± 2 N·m (89 ± 17 in-lb)
    • B: 24 ± 4 N·m (18 ± 2 ft-lb)