INSPECTION

1. Check the camshaft journal surfaces for wear and/or damage. If any is found, replace the camshaft.

   Fig. 1: Inspect the camshaft journals for damage or signs of seizure

2. Inspect the camshafts for excessive wear and damage, then replaced if found. Measure the camshaft lobe height and replace if not within the specifications given in the chart in this section.   

   Fig. 1: Exploded view of the silent shaft and related components — 1.8L engines

   To install:

3. Install the rear silent shaft bearing into the cylinder block as follows:
   1. Apply clean engine oil to the rear bearing outer circumference and bearing hole in the cylinder block.
   2. Using bearing installation tool MD998286–01 and a hammer, drive the rear bearing into the cylinder block.

      NOTE: Make sure the bearing oil holes align with the oil holes in the block, once the bearings are installed.

4. Install the front silent shaft bearing into the cylinder block as follows:
   1. Install 2 guide pins, normally included in the special tool set with bearing installer MD998289–01, to the threaded holes in the cylinder block.
   2. Set the front baring on the installation tool so that the ratchet ball of the tool fits in the hole in the bearing.
   3. Apply engine oil to the bearing outer circumference and the bearing hole in the cylinder block.
   4. Set the installation tool on the guide pins and, using a hammer, drive the bearing into the cylinder block.

      NOTE: Make sure the bearing oil holes align with the oil holes in the block, once the bearings are installed.

5. Lubricate the bearing surface of the shaft and the bearing journals with clean engine oil. Carefully install the silent shafts to the block.
6. Clean the gasket material from the mating surface of the cylinder block and the engine front cover. Install new gasket in place.
7. Using seal installation tool MD998304–01 or equivalent, install the crankshaft oil seal into the front engine cover.
8. Using the proper size socket wrench, press in the silent shaft oil seal into the front case.
9. Place pilot tool MD998285–01 or equivalent, onto the nose of the crankshaft. Apply clean engine oil to the outer circumference of the pilot tool.
10. Install the front case onto the engine block and install the retainer bolts in their original positions. Tighten retainers evenly to 12 ft. lbs. (17 Nm).
11. Install the oil pump relief plunger and spring into the bore in the front case and tighten to 33 ft. lbs. (45 Nm). Make sure a new gasket is in place.
12. Install the oil pimp drive gear and driven gear to the front case, lining up the timing marks. Lubricate the gears with clean engine oil.
13. Inspect the orientation of the silent shaft as outlined in the timing belt section of this chapter. Insert the Phillips screwdriver into the hole on the side of the engine block. Install and tighten the flange bolt to 27 ft. lbs. (37 Nm).
14. Install a new oil pump cover gasket in the groove of the front case. When installing the gasket, make sure the round side of the gasket is towards the oil pump cover.
15. Install the oil pump seal into the oil pump cover, making sure the lip is facing the correct direction. The lip of the seal should be installed against the oil it is to stop.

    NOTE: The timing of the oil pump sprocket and connected silent shaft can be incorrect, even with the timing mark aligned. Incorrect orientation of the silent shaft will result in engine vibration during operation. Follow the alignment procedure in the timing belt section of this chapter.

16. Install the timing belts and all related items. Make sure the timing and the orientation of the silent shafts is correct, using alignment tool in the hole in the left side of the engine block, as specified in the timing belt section of this chapter.
17. Install the oil pan, oil filter mounting bracket, oil switches and new oil filter to the engine. Fill the crankcase to the proper level with clean engine oil.
18. Connect the negative battery cable and start the engine. Check for proper timing and inspect for leaks.

2.0L Engine

NOTE: A special oil seal guide MD998285 and a plug cap socket tool MD998162 or exact equivalents are needed to complete this operation.

1. Disconnect the negative battery cable.
2. Remove the oil filter, oil pressure switch, oil gauge sending unit, oil filter mounting bracket and gasket. If equipped with turbocharged engine, remove the oil cooler bolt and oil cooler from the oil filter bracket.

   Fig. 2: Front case, oil pump and silent shafts — 2.0L engine

3. Raise and safely support the vehicle. Drain engine oil. Remove engine oil pan, oil screen and gasket. Remove the relief plug, gasket, relief spring and relief plunger.
4. Lower the vehicle. Using the proper equipment, support the weight of the engine.
5. Remove the front engine mount bracket and accessory drive belt.
6. Disconnect the electrical connector from the oil pressure sending unit. Remove the oil pressure sensor using special removal tool MD998054. Remove the oil filter and the oil filter bracket.
7. Remove the oil pan, oil screen and gasket.
8. Using special tool MD998162, remove the plug cap in the engine front cover. If the plug is too tight, hit the plug head with a hammer a few times and the plug should be easier to loosen.
9. Remove the plug on the side of the engine block. Insert a Phillips screwdriver with a shank diameter of 0.32 in. (8mm) into the plug hole. This will hold the silent shaft.
10. Remove the driven gear bolt that secures the oil pump driven gear to the silent shaft.
11. Remove and tag the front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation.
12. Remove the front case cover and oil pump assembly. If necessary, the silent shaft can come out with the cover assembly.
13. Remove the silent shaft oil seals, the crankshaft oil seal and front case gasket.
14. Remove the silent shafts and inspect as follows:
    1. Check the oil holes in the shaft for clogging.
    2. Check journals of the shaft for seizure, damage and contact with bearing. If there is anything wrong with the journal, replace the silent shaft bearing, silent shaft or front case.
    3. Check the silent shaft oil clearance. If the clearance is beyond the specifications, replace the silent shaft bearing, silent shaft or front case. The specifications for oil clearances are as follows:
    4. Right shaft
    5. Front — 0.0012–0.0024 in. (0.03–0.06mm)
    6. Rear — 0.0008–0.0021 in. (0.02–0.05mm)
    7. Left shaft
    8. Front — 0.0020–0.0036 in. (0.05–0.09mm)
    9. Rear — 0.0017–0.0033 in. (0.04–0.08mm)
15. If bearing replacement is required, remove the front bearing from the engine block by using tool MD998371.
16. To remove the rear silent shaft bearing from the engine block, use tool MD998372 and guide plate MD998374.

    To install:

17. Clean all mating surfaces of gasket material.
18. Install the rear silent shaft bearing into the cylinder block as follows:
    1. If installing the left rear bearing, install the guide plate MD9983774 to the cylinder block.
    2. Apply clean engine oil to the rear bearing outer circumference and bearing hole in the cylinder block.
    3. Using bearing installation tool MD998374, MD998373 and a hammer, drive the rear bearing into the cylinder block.

       NOTE: The left rear bearing has no oil holes. Make sure the oil hole in the right bearing align with the oil hole in the block, once the bearing is installed.

19. Install the front silent shaft bearings into the cylinder block, using installation tool as follows:
20. Apply clean engine oil to the rear bearing outer circumference and bearing hole in the cylinder block.
21. Using bearing installation tool MD998373 and a hammer, drive the rear bearing into the cylinder block.

    NOTE: Make sure the bearing oil holes align with the oil holes in the block, once the bearings are installed. Also, make sure that the clinch of the bearing is in the upper most position.

22. Lubricate the bearing surface of the shaft and the bearing journals with clean engine oil. Carefully install the silent shafts to the block.
23. Clean the gasket material from the mating surface of the cylinder block and the engine front cover. Install new gasket in place.
24. Install the oil pump drive gear and driven gear to the front case, lining up the timing marks. Lubricate the gears with clean engine oil. Install the oil pump cover, with new gasket in place and tighten the mounting bolts to 13 ft. lbs. (18 Nm).
25. Using seal installation tool C–3095-A or equivalent, install the crankshaft oil seal into the front engine case.
26. Using the proper size socket wrench, press in the silent shaft oil seal into the front case.
27. Place pilot tool MD998285 or equivalent, onto the nose of the crankshaft. Apply clean engine oil to the outer circumference of the pilot tool.
28. Install the front case onto the engine block and temporarily tighten the flange bolts (other than those for tightening the filter bracket). Mount the oil filter bracket with new gasket in place. Install the 4 bolts with washers and tighten to 16 ft. lbs. (22 Nm).
29. Insert the Phillips screwdriver into the hole on the side of the engine block. Secure the oil pump driven gear onto the left silent shaft by tightening the driven gear flange bolt to 29 ft. lbs. (40 Nm).
30. Install a new O-ring onto the groove in the front case. Using special socket tool, install and tighten the plug cap to 20 ft. lbs. (27 Nm).
31. Install the oil pump relief plunger and spring into the bore in the oil filter bracket and tighten to 36 ft. lbs. (50 Nm). Make sure a new gasket is in place.
32. Clean both mating surfaces of the oil pan and the cylinder block. Apply sealant in the groove in the oil pan flange, keeping towards the inside of the bolt holes. The width of the sealant bead applied is to be about 0.016 in. (4mm) wide.

    NOTE: After applying sealant to the oil pan, do not exceed 15 minutes before installing the oil pan.

33. Install the oil pan to the engine and secure with the retainers. Tighten bolts to 6 ft. lbs. (8 Nm).
34. Install the oil pressure gauge unit and the oil pressure switch. Connect the electrical harness connector.
35. Install the oil cooler secure with oil cooler bolt tigthened to 33 ft. lbs. (45 Nm).
36. Install new oil filled with clean engine oil.

    NOTE: The timing of the oil pump sprocket and connected silent shaft can be incorrect, even with the timing mark aligned. Incorrect orientation of the silent shaft will result in engine vibration during operation. Follow the alignment procedure in the timing belt section of this chapter.

37. Install the timing belts and all related items. Make sure the timing and orientation of the silent shafts is correct by inserting the alignment tool in the hole in the left side of the engine block, as specified in the timing belt section of this chapter.
38. Install any remaining components removed during disassembly.
39. Connect the negative battery cable and start the engine. Check for proper timing and inspect for leaks.