With Engine Removed

TIMING SYSTEM

COMPONENT:

COMPONENT:

REMOVAL
Engine removal is required for this procedure.





1. Remove the drive belt (A).





2. Remove the power steering pump (A).





3. Remove the air compressor (A).





4. Remove the alternator (A).





5. Remove drive belt idler (A).





6. Remove drive belt auto tensioner (A).





7. Remove water pump pulley (A).
8. Remove intake manifold.

DISASSEMBLY





1. Remove cylinder head cover.
a. Remove connector bracket (A) from LH cylinder head cover.





b. Disconnect RH ignition coil connector (A), condenser connector (B) and remove wiring bracket (C)





c. Remove LH, RH ignition coil.
d. Remove LH, RH cylinder head cover (A).





2. Set No. 1 cylinder to TDC/compression.
a. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.

NOTE: Do not rotate engine counterclockwise.





b. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration.
If not, turn the crankshaft one revolution (360°).

NOTE: Do not rotate engine counterclockwise.





3. Remove the lower oil pan (A).
Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan, and cut off applied sealer and removed lower oil pan.

NOTE: Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.





4. Remove the crankshaft damper pulley (A).





5. Remove the timing chain cover (A).

NOTE: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover





6. Install a set pin after compressing the timing chain tensioner.





7. Remove RH cam-to-cam guide (A).





8. Remove RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).





9. Remove RH timing chain guide (A).





10. Remove oil pump chain cover (A).





11. Remove oil pump chain tensioner assembly (A).





12. Remove oil pump chain guide (A).
13. Remove RH timing chain.





14. Remove oil pump chain sprocket (A) and oil pump chain (B).





15. Remove crankshaft sprocket (A) O/P RH camshaft drive).





16. Remove LH cam-to-cam guide (A).





17. Remove LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
18. Remove LH timing chain.





19. Remove LH timing chain guide (A).





20. Remove crankshaft sprocket (A) (LH camshaft drive).





21. Remove tensioner adapter assembly (A).

INSPECTION

SPROCKETS, CHAIN TENSIONER, CHAIN GUIDE, CHAIN TENSIONER ARM
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary
3. Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.

BELT, IDLER, BELT TENSIONER, PULLEY
1. Check the belt for oil or dust deposits. Replace, if necessary.
Small deposits should be wiped away with a dry cloth or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension adjusted, check the belt carefully. If any of these flaws are evident, replace the belt.

NOTE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to come into contact with oil, water and steam.

3. Inspect the idler for easy and smooth rotation and check for play or noise.

REASSEMBLY





1. The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.





2. Install tensioner adapter assembly (A).

Crankshaft Sprocket For LH Timing Chain:

3. Install crankshaft sprocket (A) (LH camshaft drive).





4. Install LH timing chain guide (A).
Tightening torque 19.60 - 24.50 Nm (2.0 - 2.5 kgf.m, 14.17 - 18.08 ft. lbs.)

LH Timing Chain:

5. Install LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow this procedure.
Crankshaft sprocket (A) -> Timing chain guide (B) ->Exhaust camshaft sprocket (c) -> Intake camshaft sprocket (D).
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
6. Install LH timing chain tensioner arm (B).
Tightening torque 18.62 - 21.56 Nm (1.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.)





7. Install chain tensioner (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)





8. Install LH cam-to-cam guide (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)

Crankshaft Sprocket For RH Timing Chain And Oil Pump:

9. Install crankshaft sprocket (A) (O/P RH camshaft drive).





10. Install oil pump chain (B) and oil pump sprocket (A).
Tightening torque 18.62 - 21.56 Nm (1.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.)
11. Install RH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow this procedure.
Crankshaft sprocket (A) -> Intake camshaft sprocket (B) -> Exhaust camshaft sprocket (C).
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.

RH Timing Chain:

12. Install RH timing chain guide (A).
Tightening torque 19.60 - 24.50 Nm (2.0 - 2.5 kgf.m, 14.17 - 18.08 ft. lbs.)





13. Install RH timing chain tensioner arm (B).





14. Install RH timing chain auto tensioner (A) and pull out the pins of hydraulic tensioners (LH & RH)
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)





15. Install RH cam-to-cam guide (A).
Tightening torque 9.80 - 11.76 Nm (1 .0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)





16. Install oil pump chain guide (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)





17. Install oil pump chain tensioner assembly (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)





18. Install oil pump chain cover (A).
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
19. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.

NOTE: Always turn the crankshaft clockwise.





20. Install timing chain cover.
a. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and ETC.
b. Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between cylinder head and cylinder block
The part must be assembled within 5 minutes after sealant was applied.
Bead width: 2.5 mm (0.1 inch)





c. After applying liquid sealant TB1217H on timing chain cover.
The part must be assembled within 5 minutes after sealant was applied.
Sealant should be applied without discontinuity.
Bead width: 2.5 mm (0.1 inch)

Bolt ID (Quantity) And Torques:

d. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
Tightening torque
B (17): 18.62 - 21.56 Nm (0.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.)
C (4): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
D (1): 58.80 - 68.80 Nm (6.0 - 7.0 kgf.m, 43.40 - 50.63 ft. lbs.)
E (1): 58.80 - 68.80 Nm (6.0 - 7.0 kgf.m, 43.40 - 50.63 ft. lbs.)
F (2): 24.50 - 26.46 Nm (2.5 - 2.7 kgf.m, 18.08 - 19.53 ft. lbs.)
G (4): 21.56 - 23.52 Nm (2.2 - 2.4 kgf.m, 15.91 - 17.36 ft. lbs.)
H (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
I (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
J (1): 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)
e. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.





21. Using SST (09231-3C100), install timing chain cover oil seal.





22. Install lower oil pan.
a. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
b. Before assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width: 2.5 mm (0.1 inch). But marked area (*) to be 5.0 mm (0.2 inch)

CAUTION:
^ Make clean the seating face before assembling two parts.
^ Remove harmful foreign matters on the sealing face before applying sealant.
^ When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
^ To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.





c. Install oil pan (A).
Uniformly tighten the bolts in several passes.
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)





23. Using SST (09231-3C300) install crankshaft damper pulley (A).
Tightening torque 284.2 - 303.8 Nm (29.0 - 31.0 kgf.m, 209.76 - 224.22 ft. lbs.)





24. Install cylinder head cover.
a. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
b. After applying sealant (TB1217H), it should be assembled within 5 minutes.
Bead width 2.5 mm (0.1 inch)
c. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.





d. Install the cylinder head cover bolts as following method.
Tightening torque 9.80 - 11.76 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 ft. lbs.)

CAUTION: Do not reuse cylinder head cover gasket.

e. Install ignition coil.





f. Connect RH ignition coil connector (A), condenser connector (B) and install wiring bracket (C).





g. Install connector bracket (A) from LH cylinder head cover.

INSTALLATION
1. Install intake manifold.





2. Install water pump pulley (A).
Tightening torque 7.84 - 9.80 Nm (0.8 - 1.0 kgf.m, 5.78 - 7.23 ft. lbs.)





3. Install drive belt auto tensioner (A).
Tightening torque 96.04 - 99.96 Nm (9.8 - 10.2 kgf.m, 70.85 - 73.74 ft. lbs.) 17.64 - 21.56 Nm (1.8 - 2.2 kgf.m, 13.02 - 15.91 ft. lbs.)





4. Install drive belt idler (A).
Tightening torque 52.92 - 57.82 Nm (5.4 - 5.9 kgf.m, 39.06 - 42.67 ft. lbs.)
5. Install alternator
6. Install air compressor
7. Install power steering pump.





8. Install drive belt (A).
Crankshaft pulley -> A/C pulley -> idler pulley -> alternator pulley -> water pump pulley -> P/S pump pulley -> tensioner pulley.
Rotate auto tensioner arm in the counter - clockwise moving auto tensioner pulley bolt with wrench.
After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.