Timing System

TIMING SYSTEM

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 generator (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.
1) 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.





2) 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. Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.

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 oil pump chain cover (A).





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





11. Remove oil pump chain guide (A).





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





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





15. Remove crankshaft sprocket (A) (Oil pump & 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).





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).





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





4. Install LH timing chain guide (A).





5. Install LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below. Crankshaft sprocket -> Timing chain guide -> 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 LH chain tensioner (A).





8. Install LH cam-to-cam guide (A).





9. Install crankshaft sprocket (A) (Oil pump & RH camshaft drive).





10. Install oil pump chain (B) and oil pump sprocket (A).





11. 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.)





12. Install RH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below. 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.








13. Install RH timing chain tensioner arm (B).
Tightening Torque: 18.62 - 21.56 Nm (1.9 - 2.2 kgf.m, 13.74 - 15.91 ft. lbs.)
14. Install RH timing chain auto tensioner (A).





15. Install RH cam-to-cam guide (A).





16. Install oil pump chain guide (A).





17. Install oil pump chain tensioner assembly (A).





18. Pull out the pins of hydraulic tensioners (LH & RH).
19. Install oil pump chain cover (A).





20. After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.

NOTE: Always turn the crankshaft clockwise.

21. 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.





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.





d. Install the new gasket (A) to the timing chain cover.





e. 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.





f. The engine should not be started for at least 30 minutes after timing chain cover assembly.
22. Using SST (09231-3C100), install timing chain cover oil seal.





23. 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.





CAUTION:
- Ensure the sealing face is clean 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 of the inner threads of the bolt holes.
- After assembly, wait at least 30 minutes before filling the engine with oil.

f. Install oil pan (A).
Uniformly tighten the bolts in several passes.





24. Using SST (09231-3C300) install crankshaft damper pulley (A).








25. 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.





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).





3. Install drive belt auto tensioner (A).





4. Install drive belt idler (A).





5. Install generator (A).





6. Install air conditioner compressor (A).





7. Install power steering pump (A).





8. Install drive belt (A).
Crankshaft pulley A/C pulley idler pulley generator 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.