Mechanical - Lancer Evolution: Removal & Installation Mitsubishi Lancer X

A: DRIVE BELT REMOVAL

To introduce the serpentine drive system with the drive belt auto-tensioner, the following operations will be required.

1. Rotate the pulley bolt of the auto-tensioner counterclockwise with an offset wrench [45°, a long offset wrench (5/8 x 11/16 inches) recommended] and insert the hexagon wrench into the auto-tensioner hole to fix the auto-tensioner.
2. Remove the drive belt.

B: CRANKSHAFT PULLEY CENTER BOLT/CRANKSHAFT PULLEY WASHER REMOVAL

1. Hold the crankshaft drive sprocket with special tools MB990767 and MD998719.
2. Loosen the crankshaft pulley center bolt and remove the crankshaft pulley center bolt and crankshaft pulley washer.

Scheme 2

1. Wipe off the dirt on the crankshaft and the crankshaft pulley as shown in the figure using a rag.
2. Wipe off the dirt on the crankshaft sprocket, the crankshaft and the crankshaft pulley as shown in the figure using a rag, and then degrease them. NOTE: Degrease them to prevent drop in the friction coefficient of the pressed area, which is caused by oil adhesion.
3. Install the crankshaft pulley.
4. Wipe off the dirt on the crankshaft pulley washer and the crankshaft pulley center bolt as shown in the figure using a rag.
5. Apply an adequate and minimum amount of engine oil to the threads of the crankshaft pulley center bolt and the lower area of the flange.
6. Hold the crankshaft pulley with special tools MB990767 and MD998719 in the same manner as removal.
7. Tighten the crankshaft pulley center bolt according to the following procedure. Tighten the crankshaft pulley center bolt to the specified torque 250 N.m (184 ft-lb). Loosen the crankshaft pulley center bolt fully. Tighten the crankshaft pulley center bolt to the specified torque 110 N.m (81 ft-lb). As shown in the illustration "A," apply the paint mark to the crankshaft pulley on the extended line of the corner adjacent to the one of the crankshaft pulley center bolt corners. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure. Tighten the crankshaft pulley center bolt by 60° once more. Make sure the paint mark of crankshaft pulley center bolt is aligned with the paint mark of crankshaft pulley as shown in the illustration "B".

Scheme 3

Scheme 4

1. Install the drive belt to each pulley as shown in the figure.
2. Set an offset wrench [45°, a long offset wrench (5/8 x 11/16 inches) recommended] to the pulley bolt of the auto-tensioner. Then, rotate the auto-tensioner counterclockwise and remove the L-shaped hexagon wrench fixing the auto-tensioner.
3. Apply tension to the drive belt while slowly turning the auto-tensioner clockwise.

Scheme 5

Required Special Tool

1. MB992103: Chain Tension Release Bar

A: ROCKER COVER ASSEMBLY REMOVAL

Loosen the rocker cover assembly mounting bolts in the order of number shown in the figure, and remove the rocker cover assembly.

Scheme 6

D: FRONT CAMSHAFT BEARING CAP ASSEMBLY REMOVAL

Loosen the mounting bolts of front camshaft bearing cap in the order of number shown in the figure, and remove the front camshaft bearing cap assembly.

Scheme 7

E: OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL

Loosen the mounting bolts of the camshaft bearing caps in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

Scheme 8

Scheme 9

Scheme 10

1. Raise slightly the transaxle side of the camshaft and camshaft sprocket assembly (exhaust side) by using the slack of the timing chain, and remove from the cam bearing.
2. Remove the timing chain from the camshaft and camshaft sprocket assembly (exhaust side) toward the timing chain case assembly, and remove the camshaft and camshaft sprocket assembly (exhaust side) toward the transaxle.
3. Remove special tool MB992103 inserted into the timing chain case assembly. CAUTION: The timing chain may snag on other parts. After removing the camshaft and camshaft sprocket assembly, never rotate the crankshaft.
4. After removing the camshaft and camshaft sprocket assembly (exhaust side), hang up the timing chain with a rope to prevent the timing chain from falling into the timing chain case assembly.

G: CAMSHAFT SPROCKET/CAMSHAFT REMOVAL

Hold the flats of the camshaft with a monkey wrench. Loosen the camshaft sprocket mounting bolts and remove the camshaft sprocket from the camshaft.

Scheme 11

H: POWER STEERING OIL PUMP ASSEMBLY REMOVAL

1. With the hose installed, remove the power steering oil pump assembly from the bracket.
2. Tie the removed power steering oil pump assembly with a string at a position where it will not interfere with the removal and installation of oil control valve.

I: OIL FEEDER CONTROL VALVE REMOVAL

A: O-RING/OIL FEEDER CONTROL VALVE INSTALLATION

Apply engine oil to the O-ring of the oil feeder control valve and install the oil feeder control valve to the cylinder head.

B: CAMSHAFT/CAMSHAFT SPROCKET INSTALLATION

Install the camshaft and camshaft sprocket assembly as follows.

Scheme 12

Scheme 13

1. Check that the knock pin is set to the right overhead position.
2. an adequate and minimum amount of engine oil to the outer of the camshaft edge and the entire insertion area around camshaft sprocket assembly.
3. Set the knock pin hole of camshaft sprocket assembly to the right overhead position, and slowly insert it into the camshaft assembly to the specified position.
4. Install the camshaft sprocket to the camshaft.
5. Apply an adequate and minimum amount of engine oil to the thread of the camshaft sprocket bolt and the lower area of the flange.
6. Clamp the flats of the camshaft and fix it in the same manner as removal.
7. Tighten the camshaft sprocket bolt to the specified torque. Tightening torque: 85 ± 5 N.m (63 ± 4 ft-lb)

C: CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (INTAKE SIDE) INSTALLATION

1. Align the intake side paint mark of the timing chain which was put at removal with the paint mark of the intake side camshaft sprocket, and install the camshaft sprocket to the timing chain.
2. Install the camshaft and camshaft sprocket assembly (intake side) to the cylinder head.

Scheme 14

1. Install the camshaft bearing caps to the cylinder heads. NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap mounting bolt to the specified torque in the order of number shown in the figure in two or three steps. Tightening torque: 12 ± 1 N.m (107 ± 8 in-lb)

E: CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION

Scheme 15

Scheme 16

1. When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure. CAMSHAFT BEARING MARK SPECIFICATION Front camshaft bearing cap Camshaft bearing identification mark Identification mark Journal diameter mm (in) 1 40.000 - 40.008 (1.5748 - 1.5751) 1 2 40.008 - 40.016 (1.5751 - 1.5754) 2 3 40.016 - 40.024 (1.5754 - 1.5757) 3
2. In the same manner as removal, insert the precision flat-tipped screwdriver through the service hole of the timing chain case, press up the ratchet of timing chain tensioner to unlock, and hold the unlocked timing chain tensioner. NOTE: Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock. CAUTION: When inserting special tool MB992103 into the timing chain case assembly, pay attention to the position of the timing chain to avoid damage to the timing chain and timing chain tension side guide. Do not insert the special tool beyond its insertion guideline. If unlocking the timing chain tensioner is insufficient, the special tool cannot be inserted to the insertion guideline. Do not insert the special tool forcibly, follow Step 2 again to unlock the timing chain tensioner and insert the special tool.
3. With the timing chain tensioner unlocked, insert special tool MB992103 inside the timing chain case assembly along the tension side of the timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (Figure A). NOTE: With the timing chain tensioner unlocked, insert the special tool along the tension side of the timing chain, according to the special tool top shape. The special tool can be inserted smoothly to the position where the special tool insertion guideline aligns with the timing chain case assembly top surface, and the spread timing chain tension side guide can be hold.
4. With the special tool inserted up to the insertion guide line, press the special tool against the intake side camshaft sprocket (Figure B) and spread and hold the timing chain tension side guide (Figure C).
5. Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner.
6. Pull up the camshaft and camshaft sprocket assembly (exhaust side) mounting area of the timing chain (Figure D) to provide allowance for easy installation of the camshaft and camshaft sprocket assembly (exhaust side) to the timing chain. CAUTION: When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.
7. Align the exhaust side paint mark of the timing chain which was put at removal with the paint mark of the exhaust side camshaft sprocket, and install the timing chain to the camshaft sprocket.
8. Install the camshaft and camshaft sprocket assembly (exhaust side) to the cylinder head.
9. Remove the special tool inserted into the timing chain case assembly inside.

F: FRONT CAMSHAFT BEARING CAP ASSEMBLY INSTALLATION

Scheme 17

1. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the camshaft bearing front cap to the specified torque in the order of the figure (1). Tightening torque: 17 ± 3 N.m (13 ± 2 ft-lb)
2. Tighten the front camshaft bearing cap again to the specified torque in the order of the figure (2). Tightening torque: 30 ± 2 N.m (23 ± 1 ft-lb)
3. After installing the front camshaft bearing cap, check that the paint marks of camshaft sprocket and of timing chain, the timing mark of crankshaft pulley, and the T-mark position of ignition timing indicator are aligned correctly.

Scheme 18

Scheme 19

1. Wipe off the sealant on the mating surface of the rocker cover assembly and the cylinder head and timing chain case assembly, and degrease the surface where the sealant is applied by white gasoline or the like.
2. Apply sealant to the joint between the cylinder head and timing chain case assembly as shown in the figure and install the rocker cover assembly to the cylinder head. Specified sealant: Three bond 1217G or equivalent NOTE: Install the rocker cover assembly within 3 minutes after the application of sealant.
3. Tighten the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure. Tightening torque: 3.0 ± 1.0 N.m (27 ± 8 in-lb)
4. Tighten again the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure. Tightening torque: 5.5 ± 0.5 N.m (49 ± 4 in-lb)

REMOVAL AND INSTALLATION

Scheme 20

Required Special Tools

1. MD998772: Valve Spring Compressor
2. MB992089: Retainer Holder C
3. MB992090: Retainer Holder Attachment
4. MB992085: Valve Stem Seal Pliers
5. MD998737: Valve Stem Seal Installer

A: FRONT CAMSHAFT BEARING CAP ASSEMBLY REMOVAL

Loosen the mounting bolts of front camshaft bearing cap in the order of number shown in the figure, and remove the front camshaft bearing cap assembly.

B: OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL

Loosen the mounting bolts of the camshaft bearing caps in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

C: VALVE TAPPET REMOVAL

Remove all of the valve tappets by hand.

Scheme 21

Scheme 22

1. Screw in special tool MB992090 to special tool MD998772 and assemble special tool MB992089. CAUTION: When removing the valve spring retainer lock, leave the piston of the cylinder in the TDC (Top Dead Center) position. The valve may fall into the cylinder if the piston is not properly in the TDC position.
2. Install special tool MD998772 (with special tools MB992090 and MB992089 attached) to the cylinder head and compress the valve spring. Then, remove the valve spring retainer lock.

E: VALVE STEM SEAL REMOVAL

Use special tool MB992085 to grip the base of the stem seal (where the outside diameter is larger) securely, and remove it by twisting it to the left and right.

Scheme 23

A: VALVE STEM SEAL INSTALLATION

Scheme 24

Scheme 25

1. Apply a small amount of engine oil to the press-fit part and lip part of the new valve stem seal.
2. Use special tool MD998737 to press-fit a new valve stem seal in the valve guide using the valve stem area as a guide.

B: VALVE SPRING INSTALLATION

Install the valve spring so that the painted side faces toward the camshaft.

Scheme 26

C: VALVE SPRING RETAINER LOCK INSTALLATION

In the same manner as removal, use special tool MD998772 with special tool MB992090 and special tool MB992089 attached to compress the valve spring, and install the valve spring retainer lock.

D: VALVE TAPPET INSTALLATION

1. Apply a small amount of engine oil to the valve tappets. CAUTION: Be sure to install the valve tappets in the same position as before.
2. Install the valve tappet to the cylinder head.

E: THRUST CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP INSTALLATION

1. Install the camshaft bearing caps to the cylinder heads. NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap to the specified torque in the order of number shown in the figure in two or three steps. Tightening torque: 12 ± 1 N.m (107 ± 8 in-lb)

F: CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION

When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure.

CAMSHAFT BEARING MARK SPECIFICATION

G: FRONT CAMSHAFT BEARING CAP ASSEMBLY INSTALLATION

1. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the front camshaft bearing cap to the specified torque in the order of the figure (1). Tightening torque: 17 ± 3 N.m (13 ± 2 ft-lb)
2. Tighten the front camshaft bearing cap again to the specified torque in the order of the figure (2). Tightening torque: 30 ± 2 N.m (23 ± 1 ft-lb)

Scheme 27

Required Special Tool

1. MD998727: Oil Pan FIPG Cutter

A: A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL

1. Remove the A/C compressor and clutch assembly together with the hose from the bracket.
2. Tie the removed A/C compressor and clutch assembly with a string at a position where they will not interfere with the removal and installation of engine oil pan.

Scheme 28

Scheme 29

Scheme 30

1. Remove the engine oil pan mounting bolts. CAUTION: Do not forcibly drive in special tool MD998727 to avoid damage to the engine oil pan seal surface of cylinder block assembly.
2. Insert special tool MD998727 from the engine oil pan removal groove of the cylinder block assembly.
3. Lightly tap the special tool with a hammer to slide the oil pan seal surface, cut off the liquid gasket, and remove the engine oil pan.

Scheme 31

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 using quick-drying degreasing agent (white gasoline).
2. Apply the sealant without any gap to the mating surface of engine oil pan as shown in the figure. Within three minutes, install the engine oil pan to the cylinder block assembly. Specified sealant: Three bond 1217G or equivalent CAUTION: Do not apply oil or water to the sealant-applied area or start up the engine within 2 hours after the installation of the engine oil pan.
3. Tighten the engine oil pan mounting bolts to the specified torque. Tightening torque: M6: 10 ± 2 N.m (89 ± 17 in-lb) M8: 29 ± 2 N.m (22 ± 1 ft-lb)

B: ENGINE OIL PAN DRAIN PLUG GASKET INSTALLATION

Replace the engine oil pan drain plug gasket with a new one. Install the new gasket in the direction shown in the illustration.

Scheme 32

C: A/C COMPRESSOR AND CLUTCH ASSEMBLY INSTALLATION

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.

Tightening torque: 23 ± 6 N.m (17 ± 4 ft-lb)

Scheme 33

A: FLYWHEEL BOLTS REMOVAL

Fix the flywheel using special tool MB991883, and loosen the flywheel bolts.

Scheme 34

Scheme 35

1. Remove all the traces of sealant adhering to the cylinder block and ladder frame using a remover or others. Then, degrease them using quick-drying degreasing agent (white gasoline).
2. Apply the sealant without any gap to the cylinder block and ladder frame as shown in the figure. Within three minutes, install the crankshaft rear oil seal case assembly. Specified sealant: Three bond 1227D or equivalent
3. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip, and install the crankshaft rear oil seal case assembly. CAUTION: Do not apply oil or water to the sealant-applied area or start up the engine within 2 hours after the installation of the crankshaft rear oil seal.
4. Tighten the crankshaft rear oil seal case assembly mounting bolts to the specified torque. Tightening torque: 10 ± 2 N.m (89 ± 17 in-lb)

Scheme 36

Scheme 37

1. Remove the engine oil and deposits from the flywheel bolt threads, crankshaft tapped hole, and flywheel.
2. Install the flywheel and flywheel hub < TC-SST > to the crankshaft.
3. Use special tool MB991883 to secure the flywheel assembly in the same manner as removal.
4. Apply a small amount of engine oil to the bearing surfaces of flywheel bolts and crankshaft tapped hole, and apply the sealant to the bolt threads of flywheel. Specified sealant: Three bond 1324 or equivalent
5. Tighten flywheel bolts to temporary torque 40 N.m (30 ft-lb) in the order shown in the illustration.
6. Tighten flywheel bolts to specified torque in the order shown in the illustration. Tightening torque: 130 N.m (96 ft-lb)

Scheme 38

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip. CAUTION: When installing the crankshaft oil seal, be careful to avoid damage to the crankshaft front oil seal.
2. Using special tool MB991448, press in the crankshaft front oil seal up to the chamfered surface of timing chain case.

Scheme 39

Scheme 40

Required Special Tools

1. MB991454: Engine Hanger Balancer
2. MB991895: Engine Hanger
3. MB991928: Engine Hanger

Scheme 41

Scheme 42

Scheme 43

1. Follow the steps below to unlock the fuel high-pressure hose connector. Insert a flat-tipped screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04inch) thick] into the retainer of the fuel high-pressure hose connector. CAUTION: When pushing up the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer. Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees to push up the retainer and unlock the fuel high-pressure hose connector.
2. Remove the fuel high-pressure hose.

B: FRONT CAMSHAFT BEARING CAP ASSEMBLY REMOVAL

Loosen the mounting bolts of front camshaft bearing cap in the order of number shown in the figure, and remove the front camshaft bearing cap assembly.

C: OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL

Loosen the mounting bolts of the camshaft bearing caps in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

Scheme 44

Scheme 45

Scheme 46

1. Temporarily install the engine oil pan which was removed at the valve timing chain removal (Refer to «OIL PAN»(ref-289376-S10320534282008063000000) ).
2. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transaxle assembly.
3. Remove special tool MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the valve timing chain was removed.
4. Loosen and remove the bolts in two or three steps in the order of number shown in the figure.

A: CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION

Scheme 47

Scheme 48

1. Remove the sealant and grease on the top surface of cylinder block and on the bottom surface of the cylinder head. Then, use the quick-drying degreasing agent (white gasoline) to degrease the sealant application surface.
2. Apply the sealant to the top surface of cylinder block as shown in the figure. Specified sealant: Three bond 1217G
3. Within three minutes after the sealant application, install the cylinder head gasket to the cylinder block. NOTE: When the cylinder gasket is installed to the cylinder block, check that the sealant is securely applied to the bead line of the cylinder head gasket.
4. Apply the sealant to the top surface of cylinder head gasket as shown in the figure. Specified sealant: Three bond 1217G CAUTION: Within two hours after the cylinder head assembly installation, do not apply oil or water to the sealant application area or start the engine.
5. Within three minutes after the sealant application, install the cylinder head assembly.

Scheme 49

Scheme 50

1. Replace the cylinder head bolt and washer with new ones.
2. For two bolts of the timing chain side, the washer can be removed from the bolt. Install the washer, with its sag facing upward, to the bolts.
3. Apply a small amount of engine oil to the thread of the bolts and to the washers.
4. Tighten the bolts by the following procedure (plastic region angular tightening method). Tighten the bolts to 35 ± 2 N.m (26 ± 1 ft-lb) in the order of number shown in the figure. CAUTION: When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure. Apply paint marks to the head of cylinder head bolt and the cylinder head. Tighten the cylinder head to 90° in the tightening order. Additionally tighten to 90°, and check that the paint mark on the cylinder head bolt is aligned with the paint mark on the cylinder head.
5. Install special tool MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the valve timing chain was removed (Refer to «TIMING CHAIN»(ref-289376-S35593109372008063000000) ).
6. Remove the garage jack which supports the engine and transaxle assembly.
7. Remove the engine oil pan installed temporarily.

C: CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY INSTALLATION

When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure.

CAMSHAFT BEARING MARK SPECIFICATION

D: THRUST CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP INSTALLATION

1. Install the camshaft bearing caps to the cylinder heads. NOTE: Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap mounting bolt to the specified torque in the order of number shown in the figure in two or three steps. Tightening torque: 12 ± 1 N.m (107 ± 8 in-lb)

E: FRONT CAMSHAFT BEARING CAP ASSEMBLY INSTALLATION

1. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the front camshaft bearing cap to the specified torque in the order of the figure (1). Tightening torque: 17 ± 3 N.m (13 ± 2 ft-lb)
2. Tighten the front camshaft bearing cap again to the specified torque in the order of the figure (2). Tightening torque: 30 ± 2 N.m (23 ± 1 ft-lb)

A: POWER STEERING OIL PUMP ASSEMBLY REMOVAL

1. Remove the power steering oil pump assembly with hose on it.
2. Tie the removed power steering oil pump with a string at a position where it will not interfere with the removal and installation of timing chain.

C: CRANKSHAFT PULLEY REMOVAL

When removing the crankshaft pulley, slightly loosen the water pump pulley mounting bolts before removal of the drive belt.

D: AUTO-TENSIONER REMOVAL

Loosen the mounting bolt of generator assembly lower part, and remove the mounting bolt of generator assembly upper part. Slide the generator assembly, and remove the auto-tensioner.

Scheme 51

E: TIMING CHAIN CASE ASSEMBLY REMOVAL

Scheme 52

Scheme 53

1. 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.

Scheme 54

1. Temporarily install the crankshaft pulley to the crankshaft. CAUTION: Turn the crankshaft clockwise.
2. 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 stroke. NOTE: At this time, it is not necessary that the link plate (blue) of the timing chain always aligns with each sprocket timing mark.
3. Remove the crankshaft pulley installed temporarily.
4. Using a flat-tipped precision screwdriver, release the ratchet of timing chain tensioner.
5. Compress the plunger of timing chain tensioner and insert hard wire (such as piano wire) or the L-shaped hexagon wrench (1.5 mm[0.05 inch]) to fix the plunger of the timing chain tensioner.
6. Remove the timing chain tensioner.

Scheme 55

Scheme 56

1. Set the timing marks of the camshaft sprockets and the crankshaft sprocket as shown in the figure.
2. Align each sprocket timing chain mating mark with the link plate (blue) of timing chain to avoid slack of the timing chain tension side, and install the timing chain to the sprockets.

Scheme 57

Scheme 58

1. Check that the sprocket timing chain mating marks align with the link plates (blue) of the 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 timing chain.

C: CRANKSHAFT FRONT OIL SEAL INSTALLATION

1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip. CAUTION: When installing the crankshaft oil seal, be careful to avoid damage to the crankshaft front oil seal.
2. Using special tool MB991448, press in the crankshaft front oil seal up to the chamfered surface of timing chain case.

D: TIMING CHAIN CASE ASSEMBLY INSTALLATION

Scheme 59

Scheme 60

1. Remove all the traces of sealant adhering to the timing chain case assembly installation surfaces of timing chain case assembly, cylinder block, and cylinder head. Then, degrease the surfaces with the quick-drying degreasing agent (white gasoline).
2. Remove all the sealant adhering to the gasket between the cylinder head and cylinder block (three-surface aligned part). Then, degrease the surfaces with the quick-drying degreasing agent (white gasoline).
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. To the timing chain case assembly mating surface, apply the sealant with a width of 2.5 ± 0.5 mm (0.1 ± 0.02 inch) and without a gap. However, with the "A" shown in the figure, apply the sealant with overlapping the diameter of 4.5 ± 0.5 mm (0.18 ± 0.02 inch) or 2.5 ± 0.5 mm (0.1 ± 0.02 inch) as shown in the figure. Specified sealant: Three bond 1217G 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. Within two hours after the timing chain case assembly installation, do not apply oil or water to the sealant application area or start the engine.
5. Within three minutes after the application of sealant, install the timing chain case assembly to the cylinder block and cylinder head so that the sealant does not contact other parts.
6. To the installation positions shown in the figure, tighten the timing chain case assembly mounting bolts to the specified torque shown below. TIGHTENING TORQUE SPECIFICATION Bolt (symbol) Thread diameter x Length mm Tightening torque Flange bolt (A) M6 x 25 10 ± 2 N.m (89 ± 17 in-lb) Flange bolt (B) M8 x 28 24 ± 4 N.m (18 ± 2 ft-lb) Bolt (C) M6 x 25 10 ± 2 N.m (89 ± 17 in-lb)

E: WATER PUMP PULLEY INSTALLATION

Temporarily tighten the water pump pulley mounting bolts. Then, tighten them to the specified torque after the installation of drive belt.

Tightening torque: 9.0 ± 1.0 N.m (80 ± 9 in-lb)

Scheme 61

Required Special Tools

1. MB991454: Engine Hanger Balancer
2. MB991895: Engine Hanger
3. MB991928: Engine Hanger
4. MB992201: Engine Hanger Plate

1. Remove the A/C compressor and clutch assembly together with the hose from the bracket.
2. Tie the removed A/C compressor and clutch assembly with a string at a position where it will not interfere with the removal and installation of engine assembly.

Scheme 62

Scheme 63

Scheme 64

1. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine assembly.
2. When the transaxle assembly is removed, remove special tool MB991928 or MB991895 which supports the engine assembly.
3. Set special tool MB991454 to the engine hanger and the power steering oil pump bracket.
4. Hold the engine assembly with a chain block.
5. Place a garage jack against the engine oil pan with a piece of wood in between, and remove the engine mounting bracket while adjusting the position of the engine.
6. After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the engine assembly slowly with the chain block to remove the engine assembly upward from the engine compartment.

A: ENGINE ASSEMBLY/ENGINE MOUNTING BRACKET INSTALLATION

1. Set special tool MB991454 and a chain block to the engine assembly.
2. Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.
3. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mounting bracket while adjusting the position of the engine.
4. Remove the chain block.
5. Install special tool MB991928 or MB991895 which is used during installation of transaxle assembly to hold the engine assembly. (Refer to «TRANSAXLE ASSEMBLY»(ref-289383-S37303928922008063000000) < M/T >), (Refer to «TRANSAXLE ASSEMBLY»(ref-289384-S42777275452008063000000) < TC-SST >)

B: A/C COMPRESSOR AND CLUTCH ASSEMBLY INSTALLATION

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.

Tightening torque: 23 ± 6 N.m (17 ± 4 ft-lb)