1. Drain oil, a drain 3 litre of coolant from radiator and remove bottom shroud, D22 has radiator drain bung.
2. Lock crankshaft up, 4th gear, bar tyre leaver through the prop shaft.
3. Loosen front crank bolt, it is very tight, use large breaker bar with pipe.
4. Remove bell housing and starter bolts, remove gearbox cross member 4 x bolts, remove crank angle sender, and slip gearbox back 25mm.
5. Remove diff cross member bolts, except 1 x closest to prop shaft, remove right hand CV 6 x bolts, remove power steer bracket mount, 14mm bolt under vac. pump.
6. Remove steering idler arm 3 x bolts from chassis.
7. Remove AC compressor 4 x bolts and AC mount to sump 2 x bolts.
8. Remove all black sump pan 10mm bolts, remove aluminium sump bolts 12mm and 10mm bolts in rear main seal housing, remove sump.
9. Remove top radiator hose, radiator shroud 2 x bolts, remove fan shroud.
10. Loosen fan, remove drive belts and remove fan.
11. Remove power steering pump, remove EGR pipe.
12. Remove front pulley, need 6 mm fine thread bolts to screw into pulley.
13. Remove plastic top timing chain cover.
14. Remove oil pump timing cover 11 x 10mm bolts, remove bottom timing cover.
WARNING after removal, check oil pump rear cover screws are tight, check for wear on oil pump drive faces. A yd25.com.au oil pump has stronger Australian made gears.
The rear cover has been redesigned so as to allow removal of the oil pump with out removal of the sump. The rear cover is available as a replacement part fitting the original oil pump housing.
15. Rotate crank and insert 5.5 mm pin into fuel pump sprocket locking hole, this is TDC.
16. Loosen vac. pump nut, fuel pump cap screws.
17. Remove all chains and guides and sprockets, except FUEL PUMP SHIM!
18. Fit fuel pump engine oil seal if supplied, remove t70 nut and sprocket boss.
19. Check cam marks are at 10 o’clock intake side and 2 o’clock exhaust side.
20. Fit vac pump sprocket, use flat washer spring washer and tube nut, apply thread locker to tube nut, wrap a rag around sprocket and tighten with impact wrench, 45 flb. With a straight edge check the alignment of vac pump and fuel pump sprockets. Various fuel pump shims are available. Ensure true alignment. Misalignment destroys chains guides and tensioners.
21. Insert crank sprocket part of the way on and hang the primary timing chain on the fuel pump sprocket marks [dot to marked link] fit chain to crank sprocket marks [notch to marked link] slowly push home.
22. Fit bottom tensioner guides and primary timing chain.
23. Fit top chain and guides as per marked links and sprocket marks.
24. Top tensioner, remove plunger, insert spacer dowel into housing, insert plunger. Fit right hand tensioner bolt, press plunger in rotate and fit left hand tensioner bolt.
25. If the crank outer woodriff key is loose super glue the woodrift key to the crankshaft, this prevents the woodrift key fall into the sump when putting the front pulley back on!
26. Rotate crank 2 x turns clock wise checking no tight spots, [the valves touching the pistons]
27. Front cover, oil pump, check for wear to the drive flat surfaces, if worn contact yd25.com.au for Australian made upgraded oil pump. Check crankshaft oil pump drive bush for surface wear. Apply silicon replace bottom timing cover and top timing chain cover.
28. File a lead into crank pulley keyway, align and tap home, torque crank bolt 55 ft lb + 120 deg grease bolt thread and face.
29. Replace sump, oil pick up, sump tank, fill with oil.
30. Start engine and test run for a few minutes.
31. Continue to replace all other parts.