Timing Chain: Service and Repair
Removal and InstallationEM-64 Component (Part 1):
EM-64 Component (Part 2):
NOTE:
^ This Information describes procedures for removing/installing front timing chain case and timing chain related parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul, etc.
^ To remove/install front timing chain case, timing chain, and its related parts without removing oil pan (upper), refer to EM-54, "Removal and Installation". Service and Repair
REMOVAL
1. Remove front tire.
2. Disconnect negative battery terminal.
3. Remove engine cover with power tool.
4. Remove air cleaner case assembly.
5. Remove front and rear engine undercover with power tool.
6. Release the fuel pressure.
7. Drain engine coolant from radiator.
CAUTION:
^ Perform this step when the engine is cold.
^ Do not spill engine coolant on drive belts.
8. Drain engine oil.
CAUTION:
^ Perform this step when the engine is cold.
^ Do not spill engine oil on drive belts.
9. Remove engine harnesses.
10. Remove intake manifold collectors (upper and lower).
11. Remove radiator cooling fan assembly.
12. Remove drive belts.
13. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside.
14. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
Refer to PS-27, "On-Vehicle Inspection and Service".
15. Remove power steering oil pump bracket. Refer to PS-27, "On-Vehicle Inspection and Service".
16. Remove alternator.
17. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
18. Remove intake valve timing control covers.
^ Loosen mounting bolts in reverse order as shown in the figure.
^ Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
19. Remove collared O-ring from front timing chain case (left and right side).
20. Remove rocker covers (right and left).
21. Remove oil pans (lower and upper).
22. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
b. Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown in the figure.
^ If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
23. Remove crankshaft pulley as follows:
a. Remove rear cover plate (2WD models) or starter motor (AWD models) and set the ring gear stopper (SST).
b. Loosen crankshaft pulley bolt and rotate bolt seating surface at 10 mm (0.39 in) from its original position.
CAUTION:
Do not remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller.
c. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through.
CAUTION:
Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
24. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
b. Insert a suitable tool into the notch at the top of front timing chain case as shown (1).
c. Pry off case by moving the tool as shown (2).
^ Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION:
^ Do not use a screwdriver or something similar.
^ After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
25. Remove O-rings from rear timing chain case.
26. Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
^ Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
27. Remove front oil seal from front timing chain case using a suitable tool.
^ Use a screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case.
28. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt.
b. Loosen upper mounting bolt slowly, and then turn timing chain tensioner (primary) on the mounting bolt so that plunger is fully expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain tensioner (primary).
29. Remove internal chain guide, tension guide and slack guide.
NOTE:
Tension guide can be removed after removing timing chain (primary).
30. Remove timing chain (primary) and crankshaft sprocket.
CAUTION:
After removing timing chain (primary), do not turn crankshaft and camshaft separately, or valves will strike the piston heads.
31. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach suitable stopper pin to the right and left timing chain tensioners (secondary).
NOTE:
^ Use approximately 0.5 mm (0.020 in) dia.hard metal pin as a stopper pin.
^ For removal of timing chain tensioner (secondary), refer to EM-83, "Component". Service and Repair
[Removing camshaft bracket (No. 1) is required.]
b. Remove camshaft sprocket (INT and EXH) mounting bolts.
^ Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts.
CAUTION:
Do not loosen the mounting bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain.
c. Remove timing chain (secondary) together with camshaft sprockets.
^ Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
^ Insert 0.5 mm (0.020 in)-thick metal or resin plate between timing chain and timing chain tensioner plunger (guide). Remove timing chain (secondary) together with camshaft sprockets with timing chain loose from guide groove.
CAUTION:
Be careful of plunger coming-off when removing timing chain (secondary). This is because plunger of timing chain tensioner (secondary) moves during operation, leading to coming-off of fixed stopper pin.
NOTE:
Camshaft sprocket (INT) is two-for-one structure of primary, and secondary sprockets.
^ When handling camshaft sprocket (INT), be careful of the following caution:
CAUTION:
^ Handle carefully to avoid any shock to camshaft sprocket.
^ Do not disassemble. (Do not loosen bolts "A" as shown in the figure).
32. Remove rear timing chain case as follows:
a. Loosen and remove mounting bolts in reverse order as shown in the figure.
b. Cut liquid gasket using the seal cutter [SST: KV10111100 (J37228)] and remove rear timing chain case.
CAUTION:
^ Do not remove plate metal cover of oil passage.
^ After removal, handle rear timing chain case carefully so it does not tilt, cant, or warp under a load.
33. Remove O-rings from cylinder head.
34. Remove O-rings from cylinder block.
35. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1).
b. Remove timing chain tensioners (secondary) with a stopper pin attached.
36. Use a scraper to remove all traces of liquid gasket from front and rear timing chain cases, and opposite mating surfaces.
^ Remove old liquid gasket from the bolt hole and thread.
37. Use a scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and any excessive wear at link plates and roller links of timing chain. Replace timing chain as necessary.
INSTALLATION
NOTE:
The below figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed.
a. Install timing chain tensioners (secondary) with a stopper pin attached and new O-rings.
b. Install camshaft brackets (No. 1).
2. Install rear timing chain case as follows:
a. Install new O-rings onto cylinder block.
b. Install new O-rings to cylinder head.
c. Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
CAUTION:
^ For "A" in the figure, completely wipe out liquid gasket extended on a portion touching at engine coolant.
^ Apply liquid gasket on installation position of water pump and cylinder head very completely.
d. Align rear timing chain case and water pump assembly with dowel pins (right and left) on cylinder block and install rear timing chain case.
^ Make sure O-rings stay in place during installation to cylinder block and cylinder head.
e. Tighten mounting bolts in numerical order as shown in the figure.
^ There are two types mounting bolts. Refer to the following for locating bolts.
Bolt length: Bolt position
20 mm (0.79 in) 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in) Except the above
Torque: 12.7 Nm (1.3 kg-m, 9 ft-lb)
f. After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure.
^ If liquid gasket protrudes, wipe it off immediately.
g. After installing rear timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface.
Standard
Rear timing chain case to cylinder block: -0.24 to 0.14 mm (-0.009 to 0.006 in)
^ If not within the standard, repeat the installation procedure.
3. Install water pump with new O-rings.
4. Make sure that dowel pin hole, dowel pin and crankshaft key are located as shown in the figure. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
Camshaft dowel pin hole (intake side)
: At cylinder head upper face side in each bank.
Camshaft dowel pin (exhaust side)
: At cylinder head upper face side in each bank.
Crankshaft key
: At cylinder head side of right bank.
CAUTION:
Hole on small dia.side must be used for intake side dowel pin hole. Do not misidentify (ignore big dia. side).
5. Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION:
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions repeatedly during the installation process.
a. Push plunger of timing chain tensioner (secondary) and keep it pressed in with a stopper pin.
b. Install timing chains (secondary) and camshaft sprockets.
^ Align the mating marks on timing chain (secondary) (gold link) with the ones on intake and exhaust camshaft sprockets (punched), and install them.
NOTE:
^ Mating marks for intake camshaft sprocket are on the back side of camshaft sprocket (secondary).
^ There are two types of mating marks, circle and oval types. They should be used for the right and left banks, respectively.
Right bank: Use circle type.
Left bank: Use oval type.
^ Align dowel pin and pin hole on camshafts with the groove and dowel pin on sprockets, and install them.
^ On the intake side, align pin hole on the small diameter side of the camshaft front end with dowel pin on the back side of camshaft sprocket, and install them.
^ On the exhaust side, align dowel pin on camshaft front end with pin groove on camshaft sprocket, and install them.
^ In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
^ Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins.
^ It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the top of sprocket teeth and its extended line in advance with paint.
c. After confirming the mating marks are aligned, tighten camshaft sprocket mounting bolts.
^ Secure camshaft using a wrench at the hexagonal portion to tighten mounting bolts.
d. Pull stopper pins out from timing chain tensioners (secondary).
6. Install tension guide.
7. Install timing chain (primary) as follows:
a. Install crankshaft sprocket.
^ Make sure the mating marks on crankshaft sprocket face the front of the engine.
b. Install timing chain (primary).
^ Install timing chain (primary) so the mating mark (punched) on camshaft sprocket is aligned with the pink link on timing chain, while the mating mark (notched) on crankshaft sprocket 'is aligned with the orange one on timing chain, as shown in the figure.
^ When it is difficult to align mating marks of timing chain (primary) with each sprocket, gradually turn camshaft using wrench on the hexagonal portion to align it with the mating marks.
^ During alignment, be careful to prevent dislocation of mating mark alignments of timing chains (secondary).
8. Install internal chain guide, slack guide and timing chain tensioner (primary).
CAUTION:
Do not overtighten slack guide mounting bolts. It is normal for a gap to exist under the bolt seats when mounting bolts are tightened to the specification.
9. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab up (or turn lever downward) so as to remove plunger stopper tab from the rachet of plunger.
NOTE:
Plunger stopper tab and lever are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin through hole of lever into tensioner body hole.
^ The lever parts and the tab are synchronized. Therefore, the plunger will be secured under this condition.
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
e. Install timing chain tensioner (primary).
^ Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary).
f. Pull out stopper pin after installing, and then release plunger.
10. Make sure again that the mating marks on sprockets and timing chain have not slipped out of alignment.
11. Install new O-rings on rear timing chain case.
12. Install new front oil seal on front timing chain case.
^ Apply new engine oil to both oil seal lip and dust seal lip.
^ Install it so that each seal lip is oriented as shown in the figure.
^ Using a suitable drift [outer diameter: 60 mm (2.36 in)], press fit oil seal until it becomes flush with front timing chain case end face.
^ Make sure the garter spring is in position and seal lip is not inverted.
13. Install water pump cover and chain tensioner cover to front timing chain case.
^ Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to front timing chain case as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
14. Install front timing chain case as follows:
a. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to front timing chain case back side as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
b. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
c. Tighten mounting bolts to the specified torque in numerical order as shown in the figure.
^ There are two types of mounting bolts. Refer to the following for locating bolts.
M8 bolts: 1, 2: 28.4 Nm (2.9 kg-m, 21 ft-lb)
M6 bolts: Except the above: 12.7 Nm (1.3 kg-m, 9 ft-lb)
d. After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).
e. After installing front timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface.
Standard
Front timing chain case to rear timing chain case: -0.14 to 0.14 mm (-0.006 to 0.006 in)
^ If not within the standard, repeat the installation procedure.
15. Install right and left intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
b. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to intake valve timing control covers as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
c. Install new collared O-rings in front timing chain case oil hole (left and right sides).
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with holes to install intake valve timing control covers.
e. Tighten mounting bolts in numerical order as shown in the figure.
16. Install oil pans (upper and lower).
17. Install rocker covers (right and left banks).
18. Install crankshaft pulley as follows:
a. Fix crankshaft using the ring gear stopper [SST: KV10117700 (J44716)].
b. Install crankshaft pulley, taking care not to damage front oil seal.
^ When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).
c. Tighten crankshaft pulley bolt.
Torque: 44.1 Nm (4.5 kg-m, 33 ft-lb)
d. Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt.
e. Further tighten by 90 degrees. (Angle tightening)
^ Check the tightening angle by referencing to the notches. The angle between two notches is 90 degrees.
19. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
20. For the following operations, perform steps in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
^ Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
^ Start engine. With engine speed increased, check again for fuel leakage at connection points.
^ Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.
^ Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from lines and hoses of applicable lines, such as in cooling system.
^ After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
