Removing
Location of the coolant supply pipe and engine lifting eye bolt
1 - pipe fastening bolt; 2 - pipe for supplying coolant; 3 - nut; 4 - bolt
Elements of fastening of an arm of the pump of the amplifier of a steering
1 - bracket; 2 - central bolt; 3 - bracket mounting bolts
Bolt location (1) bracket mounting (2) radiator fan pulley
Arrangement of bolts of fastening of the oil pallet to the bottom cover of a driving chain
The location of the remaining bolts of the lower cover of the drive chain
1. Remove the ground wire from the battery.
2. Open the hood and place it in a vertical position.
3. If equipped, remove the engine mudguard.
4. Remove the air filter.
5. Remove the radiator and fan impeller.
6. Unscrew the bolt securing the air intake pipe to the body panel and remove the pipe.
7. Remove the auxiliary drive belt.
8. Unscrew the bolts and remove the auxiliary drive belt pulleys.
9. Remove the crankshaft/vibration damper pulley and hub.
10. Unscrew the bolts and remove the coolant supply pipe coming from the front side of the cylinder head from the water pump. Remove the O-ring from the pipe and move the pipe to the side.
11. Unscrew the nut and remove the bolt securing the front engine lifting eye located on the front side of the cylinder head (see fig. Location of the coolant supply pipe and engine lifting eye bolt).
12. On models with a self-leveling rear suspension, loosen the clamp and remove the hose from the pipe on the left front side of the cylinder head. Close the hose and pipe with appropriate plugs.
13. Remove the top drive chain cover.
14. Loosen the center bolt of the power steering pump bracket, then unscrew the three bolts of the bracket (see fig. Elements of fastening of an arm of the pump of the amplifier of a steering).
15. Rotate the bracket to release the lower drive chain cover.
16. Remove the two bolts securing the power steering pump to the bracket and move the pump to the side.
17. Unscrew the bolts and remove the radiator fan pulley bracket from the drive chain cover (see fig. Location of the radiator fan pulley bracket bolts).
18. Unscrew the nut and remove the crank angle sensor located on the front side of the drive chain cover from the bracket. Remove the sensor wires and mounting brackets and move the sensor to the side.
19. Disconnect the electrical wires from the generator.
20. Unscrew the four bolts securing the generator bracket to the engine and remove the generator together with the bracket.
21. Remove the drive chain tensioner.
22. Working under the vehicle, remove the bolts securing the oil pan to the lower drive chain cover (see fig. Arrangement of bolts of fastening of the oil pallet to the bottom cover of a driving chain). Note the position of the bolts as they are of different sizes. On models with a self-levelling rear suspension system, move the system hose to the side.
23. Unscrew the remaining bolts securing the bottom cover of the drive chain. Make note of their location as the bolts have different sizes (see fig. The location of the remaining bolts of the lower cover of the drive chain).
24. Carefully remove the lower drive chain cover from the guide pins.
Installation
1. Clean the mating surfaces of the cylinder block and the lower and upper timing chain covers.
2. Check the condition of the oil pan gasket and if it is damaged, replace the oil pan gasket.
3. If necessary, replace the crankshaft front O-ring installed in the lower timing chain cover.
4. Using a screwdriver blade, remove the old O-ring from the timing chain cover.
5. Clean the o-ring seat.
6. Using a drift, install a new O-ring into the timing chain cover.
7. Wrap tape around the front end of the crankshaft when installing the timing chain cover to protect the sealing lips of the crankshaft seal.
8. Replace the gasket in the timing chain cover in the lower radiator fan bracket bolt hole.
9. Apply a thin coat of sealant to the mating surfaces of the cylinder block and lower timing chain cover.
10. Lubricate the sealing lips of the crankshaft seal with clean engine oil and, being careful, install the lower timing chain cover onto the cylinder block.
11. Install the drive chain cover mounting bolts shown in Figure Location of the remaining drive chain lower cover mounting bolts, and tighten them to the specified torque.
12. Remove the adhesive tape from the front end of the crankshaft.
13. Screw in bolts of fastening of the oil pallet to the lower cover of a driving chain and tighten them the demanded moment.
14. Install the drive chain tensioner.
15. Install the alternator with the bracket on the engine and screw the bolts, tightening them to the required torque. Connect the electrical wires to the generator.
16. Install the crankshaft angle sensor and secure it with the nut.
Attention! When installing a new lower timing chain cover, check and, if necessary, adjust the position of the crank angle sensor.
17. Install the radiator fan bracket and secure with bolts, tightening them to the required torque.
18. Reinstall the power steering pump and secure with bolts.
19. Apply a light coat of sealant to both sides of the timing chain cover bolt located on the power steering bracket.
20. Rotate the power steering pump bracket and bolt, then tighten the central mounting bolt.
21. Install the upper drive chain cover.
22. If equipped, connect the self-levelling rear suspension system hose to the pipe on the front side of the cylinder head.
23. Install the bolt and nut securing the front engine lifting eye.
24. Install a new O-ring on the coolant supply pipe, install the pipe on the pump and secure with bolts.
25. Install the crankshaft pulley/vibration damper and hub.
26. Install the auxiliary drive belt pulleys and the auxiliary drive belt.
27. Install the air intake pipe and secure it with the bolt.
28. Install the fan impeller and heatsink.
29. Install the air filter.
30. Install the lower engine mudguard.
31. Add coolant to the cooling system.
32. Check the engine oil level and top up if necessary.
33. Connect ground wire to battery.