REMOVAL & INSTALLATION
1997cc, 1796cc and 2351cc Engines
See Figures 1 through 13
You'll need a number of special tools to perform this operation. They are listed as follows:
- Disconnect the negative battery cable.
- Remove the oil filter, oil pressure switch, oil gauge sending unit, oil filter mounting bracket and gasket.
- Raise and safely support the vehicle. Drain engine oil. Remove engine oil pan.
- Lower the vehicle. Remove the timing belts.
- Remove the crankshaft sprocket (inner) and counterbalance shaft sprocket.
- Remove the front engine cover which is also the oil pump cover. Different length bolts are used. Take note of their locations. Discard the shaft seal and gasket.
- Remove the oil pump driven gear flange bolt. When loosening this bolt, first remove the plug at the bottom of the left side of the cylinder block and insert a tool approximately 3 / 8 in. in diameter into the hole. The tool will hold the silent shaft in position. The tool must be inserted at least 2.4 in. into the hole. If depth of insertion is not correct, rotate the oil pump sprocket 1 revolution, and align the timing marks. Insert the tool shaft again, and watch the amount of insertion, which should be at least 2.4 in.
- Remove the oil pump gears and remove the front case assembly. Remove the threaded plug, the oil pressure relief spring and plunger.
- Remove the shaft alignment tool, front cover and oil pump as a unit, with the left countershaft attached.
- Remove the oil pump gear and left counterbalance shaft.
To aid in removal of the front cover, a driver groove is provided on the cover, above the oil pump housing. Avoid prying on the thinner parts of the housing flange or hammering on it to remove the case.
- Remove the right counterbalance shaft from the engine block.
- Using special bearing puller tool 09212 32000 or equivalent, remove the right counterbalance shaft bearing from the cylinder block.
- Using special bearing puller tool 09212 32100 and holding fixture 09212-32300 (to hold the puller) or equivalents, remove the left countershaft rear bearing from the cylinder block.
- Coat the inner surfaces of the new bearings and the block bores with clean engine oil.
- Install the left rear countershaft bearing into the cylinder block bore and install it using special bearing installer tool 09212-32200 and the special holding fixture 09212-32300 used before to remove the bearing. The fixture serves as a guide for the bearing installer tool.
- Using special bearing installer tool 09212 32200 or equivalent, install the right countershaft front bearing into the block.
- Install a new front seal in the cover. Install the oil pump drive and driven gears in the front case, aligning the timing marks on the pump gears.
- Install the left counterbalance shaft in the driven gear and temporarily tighten the bolt.
- Install the right counterbalance shaft into the cylinder block.
- Install an oil seal guide on the end of the crankshaft and install a new gasket on the front of the engine block for the front cover.
- Install a new front case packing.
- Insert the left counterbalance shaft into the engine block and at the same time, guide the front cover into place on the front of the engine block.
- Install an O-ring on the oil pump cover and install it on the front cover.
- Tighten the oil pump cover bolts and the front cover bolts to 11-13 ft. lbs. (15-18 Nm).
- Install the upper and lower under covers.
- Install the spacer on the end of the right counterbalance shaft, with the chamfered edge toward the rear of the engine.
- Install the counterbalance shaft sprocket and temporarily tighten the bolt.
- Install the inner crankshaft sprocket and align the timing marks on the sprockets with those on the front case.
- Install the inner tensioner (B) with the center of the pulley on the left side of the mounting bolt and with the pulley flange toward the front of the engine.
- Lift the tensioner by hand, clockwise, to apply tension to the belt. Tighten the bolt to secure the tensioner.
- Check that all alignment marks are in their proper places and the belt deflection is approximately 1 / 4 - 1 / 2 in. on the tension side.
When the tensioner bolt is tightened, make sure the shaft of the tensioner does not turn with the bolt. If the belt is too tight there will be noise and if the belt is too loose, the belt and sprocket may come out of mesh.
- Tighten the counterbalance shaft sprocket bolt to 22-h28.5 ft. lbs. (29-h40 Nm).
- Install the flange and crankshaft sprocket. Tighten the bolt to 43-h50 ft. lbs. (58-h67 Nm).
- Install the camshaft spacer and sprocket. Tighten the bolt to 44-h57 ft. lbs. (61-h75 Nm).
- Align the camshaft sprocket timing mark with the timing mark on the upper inner cover.
- Install the oil pump sprocket, tightening the nut to 25-h28 ft. lbs. (34-h39 Nm). Align the timing mark on the sprocket with the mark on the case.
To be assured that the phasing of the oil pump sprocket and the left counterbalance shaft is correct, a metal rod should be inserted in the plugged hole on the left side of the cylinder block. If it can be inserted more than 2.4 in., the phasing is correct. If the tool can only be inserted approximately 1.0 in., turn the oil pump sprocket through 1 turn and realign the timing marks. Keep the metal rod inserted until the installation of the timing belt is completed. Remove the tool from the hole and install the plug, before starting the engine.
- Install the tensioner spring and tensioner. Temporarily tighten the nut. Install the front end of the tensioner spring (bent at right angles) on the projection of the tensioner and the other end (straight) on the water pump body.
- If the timing belt is correctly tensioned, there should be about 12mm clearance between the outside of the belt and the edge of the belt cover. This is measured about halfway down the side of the belt opposite the tensioner.
- Complete the assembly by installing the oil screen, gasket and oil pan.
- Install the crankshaft pulley, alternator and accessory belts and adjust to specifications.
- Install the radiator, fill the cooling system with antifreeze and the crankcase with clean engine oil. Connect the negative battery cable and start the engine.