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REMOVAL & INSTALLATION

2.0L And 2.4L Engines
  1. Disconnect the negative battery cable.
  2. Remove the timing belts by following the directions for removal of the timing belts found in this section.
  3. Remove the oil filter. Drain the engine oil.

    CAUTION
    Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  4. Remove the oil pan by following the previously outlined procedures.
  5. Remove the oil pick up screen and gasket.
  6. Remove the plug from the left side of the cylinder block and insert a screwdriver-sized prytool to keep the left silent shaft in place. The prytool should have a shaft diameter of 0.3 in. (8mm) and a shaft length of at least 2.4 in. (60mm).
  7. Remove the bolt holding the oil pump sprocket and remove the sprocket.
  8. Loosen the mounting bolt for the right silent shaft sprocket until it can be turned with your fingers. Do not remove it.
  9. If not already done, remove the tensioner for the silent shaft belt (tensioner B).
  10. If not already done, remove the silent shaft belt (timing belt B). Remove the crankshaft pulley for the silent shaft belt, if so desired.

    WARNING
    After the timing belt has been removed, do not attempt to loosen the silent shaft bolt by holding the sprocket with pliers. If the sprocket is to be removed, hold the pulley with your fingers.

  11. Remove the front case mounting bolts; remove the front case assembly and its gasket.

    WARNING
    The front case bolts are of several different lengths and must be replaced exactly as removed. Labeling or diagramming their placement during removal is very important.

  12. Remove the prytool from the left silent shaft. Remove the silent shafts from the engine.
  13. Remove the oil pump cover from the front case.
  14. Remove the oil pump gears.

    Fig. 1: Oil pump and silent shaft assembly — 2.0L engine

    Fig. 2: Use a prytool to block the left silent shaft

    Fig. 3: Removing the oil pump cover from the front case

    Fig. 4: Carefully align the marks on the oil pump gear

    Fig. 5: Seal guide tool in place — note the engine is removed and inverted

    Fig. 6: Correct bolt placement by length — 2.0L and 2.4L engines

    To install:

  15. Visually check the contact surfaces of the oil pump cover and the front case for wear. If excessive wear is present, replace the components. Inspect the oil passages for clogging and clean them as needed. The silent shafts should be inspected for any of wear or seizure. Closely inspect the oil seals on the front case, replacing any with worn or damaged lips.
  16. Insert the relief plunger into the oil filter bracket and check for smooth operation.
  17. Apply engine clean engine oil to the oil pump gears and install them in the front case. Align the mating marks.
  18. Install the oil pump cover to the front case and tighten the bolts to 16 ft. lbs. (21 Nm).
  19. Carefully install the left and right silent shafts into the engine; the bearings can be damaged by careless installation.
  20. Install a seal guide tool such as MD 998285–01 or its equivalent to the crankshaft. Note that the tapered end should face away from the block. Coat the surface of the guide with clean engine oil. This guide will help in installing a new seal in the front case. If the seal is already in place, the guide will protect the seal during installation.
  21. Install a new front case gasket, carefully aligning all the bolt holes.
  22. Install the front case to the block and lightly tighten the eight bolts. When the case is properly seated, the seal guide may be removed.
  23. Insert a prytool through the left side access hole and block the left silent shaft.
  24. Install the silent shaft end bolt and tighten it to 26 ft. lbs. (35 Nm).
  25. Install the oil filter bracket and gasket. Tighten the front case mounting bolts to 17 ft. lbs. (23 Nm) and the oil filter bracket bolts.
  26. Install the plug cap at the end of the left silent shaft.
  27. Coat the relief plunger and spring in clean engine oil and install them into the oil filter bracket. Install the relief plug and gasket, tightening the plug to 34 ft. lbs. (46 Nm).
  28. Install the oil screen and gasket.
  29. Install the oil pan.
  30. Install a new oil filter.
  31. Check that the timing marks are still aligned. Push down on the center of the tension side of the belt with your finger. Correct belt deflection is approximately 1⁄4 in. (5–7mm). If the deflection is not correct, the tensioner must be released fully and the belt re-tensioned.
  32. Install the flange and the crankshaft sprocket onto the crankshaft. Make certain the flange is installed in the correct direction. If it is put on incorrectly, the belt will wear and break.
  33. Install the special washer and the sprocket retaining bolt to the crankshaft. Tighten the bolt to 88 ft. lbs. (119 Nm).
  34. Install the camshaft sprocket to the camshaft and tighten the bolts to 66 ft. lbs. (89 Nm).
  35. Install the spacer, tensioner and tensioner spring if they were removed. Install the lower end of the spring to its position on the tensioner, then place the upper end in position at the water pump. Move the tensioner towards the water pump and temporarily tighten it in this position.
  36. Install the oil pump sprocket, tightening the nut to 40 ft. lbs. (54 Nm). Remember that the oil pump drives the left silent shaft, which is still blocked by the screwdriver. Hold the sprocket by hand when tightening the nut.
  37. Double check the alignment of the timing marks for the cam, crank and oil pump sprockets. If any adjustment is needed to the oil pump sprocket, remove the screwdriver blocking the silent shaft before adjusting the sprocket. Once everything is aligned, replace the screwdriver in the left side of the block and leave it there until installation of the timing belt is complete.

    NOTE: If the screwdriver can only be inserted about 1 in. (25mm) or less, the shaft is out of position. Turn the oil pump sprocket through one full turn clockwise; the screwdriver should then go in about 2 1⁄2 in. (63mm).

  38. Install the timing belt onto the crankshaft sprocket, the oil pump sprocket and the cam sprocket in that order. Keep the belt taut between sprockets. If reusing an old belt, make certain that the direction of rotation arrow is properly oriented.
  39. Loosen the tensioner mounting nut and bolt. The spring will move the tensioner against the belt and tension it.
  40. Check the belt as it passes over the camshaft sprocket. The belt may tend to lift in the area to the left of the sprocket (roughly 7 o'clock to 12 o'clock when viewed from the pulley end.) Make certain the belt is well seated and not rubbing on any flanges or nearby surfaces.
  41. At the tensioner, tighten the bolt in the slotted hole first, then tighten the nut on the pivot. If this order is not followed, the belt will become too tight and break.
  42. Once again, check all the timing marks for alignment. Nothing should have changed; check anyway.
  43. Remove the prytool blocking the left side silent shaft. Using a socket on the crankshaft bolt, turn the crankshaft clockwise smoothly one full turn (360°). Do NOT turn the engine backwards.
  44. Loosen the tensioner nut and bolt. The spring will allow the tensioner to tighten a little bit more because of the slack picked up during engine rotation. Tighten the bolt, then the nut to 36 ft. lbs. (48 Nm).
  45. Check the deflection of the belt. At the middle of the right (tension) side of the belt, deflect the belt outward with your finger, toward the timing case. The distance between the belt and the line of the cover seal should be about 9⁄16 in. (14mm).
  46. Install the lower and upper timing belt covers. Make certain the gaskets are properly seated in the covers and that they don't come loose during installation. Tighten the bolts to 8 ft. lbs. (11 Nm).
  47. Install the crankshaft pulley.
  48. Install the water pump pulley, and install the belt. Adjust the belt to the correct tension.
  49. Install the correct amount of motor oil.
  50. Connect the negative battery cable. Start the engine and let it idle, listening for any unusual noises from the area of the timing belt. Possible causes of noise are the belt rubbing against the covers or a sprocket flange, the belt being too loose and slapping, or a tensioner binding. Do not accelerate the engine if abnormal noises are heard from the timing belt train — severe damage can result.
2.3L Diesel Engine
  1. Elevate and safely support the vehicle.
  2. Drain the engine oil.

    CAUTION
    Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  3. Remove the oil pan.
  4. Remove all of the drive belts and any other accessories which are in the way of the timing belt covers.
  5. Remove the upper timing belt cover. Note that the bolts are of different lengths; diagram their location for proper reinstallation.
  6. Rotate the engine by hand (clockwise) until all the timing marks align. This positions No. 1 cylinder at TDC on the compression stroke.
  7. If the timing belts are to be reused, mark the direction of rotation on the belt with chalk or a felt marker.
  8. Remove the center bolt holding the crankshaft pulley and remove the pulley. Do not turn the engine out of position during this removal.
  9. Remove the lower timing belt cover.
  10. Slightly loosen the retaining (lock) bolts for the timing belt tensioner. Move the tensioner towards the water pump and tighten the bolts; this holds the tensioner in the slack position.

    NOTE: If the silent shaft timing belt is not being removed, DO NOT loosen the tensioner for the silent shaft belt.

  11. Remove the camshaft sprocket and the injection pump sprocket. Do not let either shaft turn out of place during the removal. Remove the timing belt without forcing or kinking it.
  12. If the silent shaft belt is to be removed, the silent shafts must be locked in place. On the right side, remove the rubber plug from the silent shaft case and insert a thin prytool; the shaft should have a diameter of 0.32 in. (8mm). On the left side, remove the cover panel from the silent shaft case and insert a broad round bar or prytool, about the size of a short extension for a socket wrench.
  13. Remove the silent shaft sprockets; label each sprocket so it may be reinstalled in its original position. Remove the timing belt.

    Fig. 7: Oil pump and silent shaft assembly — 2.3L diesel engine

    Fig. 8: Installing the front cover oil seal

  14. Check the belt carefully for damage, wear or deterioration. Check the teeth carefully for any cracking at the base or separation from the backing. Do not use detergents or solvents to clean the belt or the sprockets. Clean them only with dry cloths or brushes. Pay particular attention to the edges of the belt; they should not be frayed or worn.
  15. Remove the upper front case. The oil seal in the case should be carefully removed and discarded. This seal must be replaced any time the case is removed.
  16. Remove the lower front case.
  17. Before removing the inner and outer drive gears, make alignment marks on both gears for reference during reassembly.
  18. Remove the oil pump.
  19. Remove the oil pump cover from the front case.
  20. Remove the oil pump gears.
  21. Visually check the contact surfaces of the oil pump cover and the front case for wear. If excessive wear is present, replace the components. Inspect the oil passages for clogging and clean them as needed. The silent shafts should be inspected for any wear or seizure. Closely inspect the oil seals on the front case, replacing any which have worn or damaged lips.
  22. If the silent shafts are to be removed, do so by lifting each out of its housing. Handle the shafts carefully and do not damage the bearing surfaces.

    To install:

  23. When reinstalling the silent shafts, coat each one liberally with clean engine oil. Tighten the chamber cover bolts to 3.5 ft. lbs (5 Nm).
  24. Install the oil pump gears in the same direction as before. Take great care to align the the marks.
  25. Coat the gears with a light coat of clean engine oil before installing the oil pump cover.
  26. Install the oil pump cover to the front case and tighten the bolts to 16 ft. lbs. (22 Nm).
  27. Install the oil pump.
  28. Install a seal guide tool such as MD 998393 or its equivalent to the crankshaft. Note that the tapered end should face away from the block. Coat the surface of the guide with clean engine oil. This guide will help in installing a new seal in the front case. If the seal is already in place, the guide will protect the seal during installation.
  29. Install a new front case gasket, carefully aligning all the bolt holes.
  30. Install the upper and lower front cases to the block and lightly tighten the bolts. When the case is properly seated, the seal guide may be removed.
  31. Install the crankshaft sprocket for the silent shaft belt, the flange and the timing belt sprocket. Make certain the sprockets and flange are installed in the correct positions; if either sprocket is installed backwards, the belt may jump off or become damaged.
  32. Install the crankshaft pulley.
  33. Install the injection pump sprocket and flange.
  34. Install the spacer on the left silent shaft with its tapered end inward or toward the oil seal. If the spacer is not placed correctly, the oil seal will be damaged.
  35. Install the silent shaft sprockets and flanges, tightening the bolts to 28 ft. lbs. (38 Nm). The shafts must be held in place with the tools used during disassembly.
  36. The tensioner for the silent shaft belt should still be in the slack position. Align the timing mark of the crankshaft sprocket if necessary.
  37. Align the timing marks of each silent shaft sprocket.
  38. Install the silent shaft timing belt (belt B), making certain that there is no slack between the crankshaft pulley and the right (upper) silent shaft.
  39. The tensioner for the timing belt (belt A) should be in the slack position. Double check the alignment of all three pulleys for belt A; the timing marks should all align.
  40. Install the timing belt.
  41. Install the upper and lower timing belt covers.
  42. Install the oil pan.
  43. Install the drive belts and other accessories removed for the procedure.
  44. Lower the vehicle back to the ground.
  45. Fill the engine fluids and double check the engine compartment for loose wires, etc.
  46. Perform any engine adjustments needed.
2.6L Engine
  1. Remove the timing chains and sprockets, following procedures outlined previously in this Section.
  2. Drain the engine oil and remove the oil filter.

    CAUTION
    Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  3. Disconnect the oil cooler bypass valve and the oil pipe joint at the filter bracket.
  4. Remove the bracket bolt and nut. Remove the bushing and remove the oil filter bracket from the engine. Remove both O-rings from the filter bracket.
  5. Remove the oil pan and gasket, following procedures outlined previously in this Section.
  6. Remove the oil pick-up screen and gasket.
  7. Remove the plug, relief spring and plunger from the side of the oil pump body.
  8. Remove the flange bolts and remove the oil pump body. Don't lose the small pins in the case.
  9. Remove the driven gear and drive gear. Don't lose the woodruff key in the end of the silent shaft.
  10. Remove the oil pump cover and its gasket.
  11. If the left silent shaft is to be removed, the thrust plate must be extracted first. Install two 8 mm diameter bolts into the threaded holes of the flange and turn the bolts to remove the thrust plate by forcing it outward.
  12. If desired, remove the right silent shaft.

    Fig. 9: Oil pump and silent shaft assembly — 2.6L engine

    Fig. 10: Removing the thrust plate

    Fig. 11: The silent shaft journals must be lightly coated with oil before installation

    Fig. 12: Use the guides to locate the thrust plate correctly

    Fig. 13: Carefully align the marks on the oil pump gears

    Fig. 14: Pre-lube the oil pump before installation

    To install:

  13. Visually check the contact surfaces of the oil pump cover and the front case for wear. Use a straight edge and a feeler gauge to measure the clearance between the gears and the case. Maximum allowable clearance is 0.0060 in. (0.15mm). If excessive wear is present, replace the the gears or case as needed.Inspect the oil passages for clogging and clean them as needed. The silent shafts should be inspected for any of wear or seizure.
  14. Insert the relief plunger into the front case and check for smooth operation.
  15. Apply a light coat of engine oil to the silent shaft journals and carefully reinstall the shafts. Use care not to damage the bearings during installation.
  16. Install a new O-ring on the thrust plate and apply a light coat of engine oil around the O-ring.
  17. Before installing the thrust plate, make two guides by cutting off the heads of two 6 mm bolts. The bolts should be 2 in. (50mm) long. Install the bolts in the threaded holes.
  18. Install the thrust plate into the cylinder block along the guides. Without the guide bolts, it will be almost impossible to align the bolt holes. While holding the thrust plate in place, remove the guide bolts one at a time and install the bolts and tighten them to 8 ft. lbs. (11 Nm).
  19. Apply engine clean engine oil to the oil pump gears and install them in the oil pump body. Align the mating marks. If the marks are not aligned, the silent shaft will be out of phase and engine vibration will occur.
  20. Place a new oil pump gasket in position and install the cover, tightening the bolts to 8 ft. lbs. (11 Nm).
  21. Hold the oil pump body in hand in the same relative position as it will be on the engine and put clean engine oil into the delivery port.
  22. Install the pump body. Tighten the large flange bolts to 48 ft. lbs. (65 Nm). The smaller screws and bolts should be tightened only to 7 ft. lbs. (10 Nm).
  23. Assemble the relief plunger and spring into the pump body and tighten the plug to 28 ft. lbs. (38 Nm).
  24. Install the oil pick–up screen with a new gasket.
  25. Install the oil pan and gasket.
  26. Replace the O-rings and install the oil filter bracket.
  27. Install a new oil filter.
  28. Install the correct amount of engine oil.
  29. Reinstall the timing chains, sprockets and all other accessories.
3.0L and 3.5L Engines

WARNING
The use of the correct special tools or their equivalent is most important for this procedure. The crankshaft sprocket must be removed and installed with the use of tools MB 990767–01 and MB 998715 or their equivalents. Attempts to use other tools or methods may cause damage to the sprocket and/or crankshaft.

  1. Disconnect the negative battery cable.
  2. Remove the dipstick.
  3. Raise the vehicle and support safely.
  4. Remove the timing belt by following the previously described directions in this section.
  5. Drain the engine oil and remove the oil pan from the engine. Remove the oil pickup — refer to the previously described procedures in this section.
  6. Remove the oil pump mounting bolts and remove the pump from the front of the engine.

    NOTE: Note the position of each oil pump case retaining bolts to facilitate installation. The bolts are of different length.

    Fig. 15: Oil pump bolt location — 3.0L Engines, other engines similar

    Fig. 16: Use correct tools to install the crankshaft seal — 3.0L Engine

    To install:

  7. Clean the gasket mounting surfaces of the pump and engine block.
  8. Prime the pump by pouring fresh oil into the inlet and turning the rotors or by packing pump with petroleum jelly. Using a new gasket, install the oil pump on the engine and tighten all bolts to 11 ft. lbs. (15 Nm).
  9. Install the balancer and crankshaft sprockets.
  10. Clean out the oil pickup or replace as required. Replace the oil pickup gasket ring and install the pickup to the pump.
  11. Install the timing belt, oil pan and all related parts.
  12. Install the dipstick. Fill the engine with the proper amount of oil.
  13. Connect the negative battery cable. Start the engine and check for proper oil pressure. Check for leaks.

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