Front Timing Chain Case

"The content of this article/image reflects the changes identified in TSB-NTB10-001"

ON-VEHICLE REPAIR

FRONT TIMING CHAIN CASE






1. O-ring
2. Collared O-ring
3. Intake valve timing control cover (RH)
4. Idler pulley
5. Drive belt auto tensioner
6. Intake valve timing control cover (LH)
7. Collared O-ring
8. O-ring
9. Chain tensioner cover
10. Cooling fan bracket
11. Crankshaft pulley
12. Front oil seal
13. Water pump cover
14. Front timing chain case
15. O-ring
A. Refer to Installation

Removal and Installation

REMOVAL

1.Remove engine room cover.
2.Drain engine oil.

CAUTION:
- Perform this step when engine is cold.
- Do not spill engine oil on drive belts.

3. Drain engine coolant from radiator.

CAUTION:
- Perform this step when engine is cold.
- Do not spill engine coolant on drive belts.

4. Remove engine cooling fan (Motor driven type).
5. Disconnect engine harnesses and remove harness brackets from front timing chain case.
6. Remove EVAP canister purge volume control solenoid valve, if necessary.
7. Remove drive belt.
8. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
9. Remove power steering oil pump bracket.
10. Remove generator.
11. Remove water bypass hoses and water hose clamp.
12. Remove engine cooling fan (Crankshaft driven type) and fan bracket.
13. Remove water hose at oil cooler.
14. Remove oil cooler water bypass pipe from front timing chain case.






15. Remove right and left intake valve timing control covers.
- Loosen bolts in reverse order as shown.
- Cut liquid gasket for removal using Tool.

Tool number : KV10111100 (J-37228)

CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.






16. Remove collared O-rings from front timing chain case (left and right side).
17. Remove A/C compressor bolts and temporarily secure A/C compressor aside.
18. Remove crankshaft pulley as follows:
a. Remove access plate and install Ring Gear Stopper Tool.

Tool number : (J-48761)






b. Loosen crankshaft pulley bolt so that there is a 10 mm (0.39 in) gap between bolt and crankshaft pulley.

CAUTION:
Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place to protect the crankshaft pulley from dropping.

c. Pull crankshaft pulley with both hands to remove it.







19. Loosen two bolts in front of oil pan (upper) in reverse order as shown.






20. Remove front timing chain case as follows:
a. Loosen bolts with power tool in reverse order as shown.






b. Insert suitable tool into the notch at the top of the front timing chain case as shown (1).
c. Pry off case by moving tool as shown (2).
- Cut liquid gasket for removal using Tool.

Tool number : KV10111100 (J-37228)

CAUTION:
- Do not use screwdriver or something similar.
- After removal, handle front timing chain case carefully so it does not twist, bend, or warp under a load.






21. Remove O-rings from rear timing chain case.
22. If necessary, remove water pump cover and chain tensioner cover from front timing chain case.
- Cut liquid gasket for removal using Tool.

Tool number : KV10111100 (J-37228)






23. Remove front oil seal from front timing chain case using suitable tool.

CAUTION:
Be careful not to damage front timing chain case.

24. Remove idler pulley, if necessary.






25. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases, oil pan (upper), and liquid gasket mating surfaces.

CAUTION:
Be careful not to allow gasket fragments to enter oil pan.






- Remove old liquid gasket from bolt hole and thread.






26. Use a scraper to remove all traces of old liquid gasket from water pump cover, chain tensioner cover (if necessary) and intake valve timing control covers.


INSTALLATION






1. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.






2. Install new front oil seal on the 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.






- Press-fit oil seal until it becomes flush with front timing chain case end face using suitable drift [outer diameter: 60 mm (2.36 in)].
- Make sure the garter spring is in position and seal lip is not inverted.

CAUTION:
- Be careful not to damage front timing chain case and crankshaft.
- Press-fit straight and avoid causing burrs or tilting oil seal.






3. Install water pump cover and chain tensioner cover to front timing chain case, if removed.
- Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown.
Use Genuine RTV Silicone Sealant or equivalent.

Tool number : WS39930000

4. Install idler pulley, if removed.
5. Install front timing chain case as follows:






a. Apply a continuous bead of liquid gasket using Tool to front timing chain case back side as shown.
Use Genuine RTV Silicone Sealant or equivalent.

Tool number : WS39930000






b. Install new O-rings on rear timing chain case.
c. Assemble front timing chain case as follows:






i. Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely.






ii. Since front timing chain case is offset for difference of bolt holes, tighten bolts temporarily while holding front timing chain case from front and top as shown.
iii. Same as the previous step, insert dowel pin while holding front timing chain case from front and top completely.






d. Tighten bolts to the specified torque in numerical order as shown.
e. After all bolts are tightened, retighten them to the specified torque in numerical order as shown.
- There are two type of bolts

Bolt position Bolt diameter
1 - 5 : 10 mm (0.39 in)
6 - 25 : 6 mm (0.24 in)
Bolt position Tightening specification
1 - 5 : 55.0 N-m (5.6 kg-m, 41 ft-lb)
6 - 25 : 12.7 N-m (1.3 kg-m, 9 ft-lb)






6. Install two bolts in front of oil pan (upper) in numerical order as shown.

Front oil pan bolts : 22.0 N-m (2.2kg-m, 16 ft-lb)






7. 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 using Tool to intake valve timing control covers as shown.
Use Genuine RTV Silicone Sealant or equivalent.

Tool number : WS39930000






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 the holes to install intake valve timing control covers.






e. Tighten bolts in numerical order as shown.

8. Install crankshaft pulley as follows:
a. 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).
b. Tighten crankshaft pulley bolt in two steps.

Step 1 : 44.1 N-m (4.5 kg-m, 33 ft-lb)
Step 2 : 84� - 90� degrees clockwise

c. Remove Ring Gear Stopper Tool.

Tool number : (J-48761)

9. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
10. Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION

- Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level.
- Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oil/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary.
- Summary of the inspection items:






Timing Chain






1. Internal chain guide
2. O-ring
3. Timing chain tensioner (secondary) (RH)
4. Camshaft sprocket (EXH)
5. Timing chain (secondary)
6. Timing chain (primary)
7. Camshaft sprocket RH (INT)
8. Camshaft sprocket LH (INT)
9. Slack guide
10. Timing chain tensioner (primary)
11. Crankshaft sprocket
12. Timing chain tensioner (secondary) (LH)
13. O-ring
14. Tension guide

Removal and Installation

CAUTION:
- After removing timing chains, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons.
- When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
- Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets, camshaft brackets, and crankshaft pulley.

NOTE:
It is not necessary to remove the rocker covers or intake manifold collector to remove or install the timing chain(s).

REMOVAL






1. Set No. 1 cylinder to TDC.
- Rotate crankshaft pulley clockwise to align timing mark (A) (grooved line without color) with timing indicator (B).
2. Remove front timing chain case. Refer to EM-1, Front Timing Chain Case.
3. Check timing chain markings to confirm No. 1 cylinder is at TDC of its compression stroke.
- If not, remove Ring Gear Stopper Tool and turn crankshaft clockwise 360� (one revolution).
- Re-install Ring Gear Stopper Tool.

Tool number : (J-48761)

- If the original timing chain markings are not legible, use paint or equivalent to mark the timing chains to the sprockets.

4. If removing the secondary timing chains, loosen camshaft sprocket bolts.






5. Compress the primary timing chain tensioner.
1. Loosen clip of primary timing chain tensioner, and release plunger stopper (1).
2. Depress plunger into tensioner body by pressing slack guide (2).
3. Keep slack guide pressed and insert stopper pin through the tensioner body hole and plunger groove (3) to hold plunger in.
- Use stopper pin included with Tool J-50246.






6. Remove internal chain guide.
7. Remove timing chain (primary).

Caution:
After removing timing chain (primary), do not turn crankshaft and camshaft separately, or valves will strike the piston heads.

8. Remove crankshaft sprocket, if necessary.






9. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach stopper pin to the right and left timing chain tensioners (secondary).

NOTE:
- Use stopper pin included with Tool J-50246.

b. Remove camshaft sprocket (INT and EXH) bolts.






c. Remove timing chain (secondary) together with camshaft sprockets.
- Turn camshaft slightly to secure slack 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).

NOTE:
Camshaft sprocket (INT) is a one piece integrated design with sprockets for timing chain (primary) and for timing chain (secondary).






-When handling camshaft sprocket (INT), be careful of the following:

CAUTION:
- Handle carefully to avoid any shock to camshaft sprocket.
- Do not disassemble. (Do not loosen bolts (A) as shown).

NOTE:
For removal of timing chain tensioner (secondary)






INSPECTION AFTER REMOVAL

Check for cracks and any excessive wear at link plates. Replace chain if necessary.
- Inspect all timing chains and associated parts for wear or damage, replace as necessary.

INSTALLATION










NOTE:
The figure above shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.






1. Make sure that dowel pin hole, dowel pin of camshaft and crankshaft key are located as shown. (No. 1 cylinder at compression TDC)

NOTE:
Though camshaft does not stop at the position as shown, 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.



2. 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 stopper pin.

- Use stopper pin included with Tool J-50246.






b. Before installing timing chains (secondary) and camshaft sprockets, confirm mating marks are visible. If necessary, use paint or equivalent to re-mark the camshaft sprockets at each mating mark.






c. Install timing chains (secondary) (8) and camshaft sprockets [INT (1) and EXH (9)].
- Left bank mating marks (6)
- Align the timing chain mating marks (secondary) (2) with the ones on camshaft sprockets (INT and EXH) (4), (5), (7) and (10) (punched), and install them.

Model Year 2005 - 2007 2008 - 2010
Mating mark (2) Copper link Blue link

NOTE:
- Mating marks for camshaft sprocket (INT) are on the back side of camshaft sprocket (secondary).
- There are two types of mating marks, circle (7), (10) and oval (4), (5) types. They should be used for the right and left banks, respectively.

Right bank : Use circle type (7) and (10).
Left bank : Use oval type (4) and (5).

- Align dowel pin (3) and pin hole on camshafts with the groove (11) 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 (3) on the back side of camshaft sprocket, and install them.

- On the exhaust side, align dowel pin on camshaft front end with pin groove (11) on camshaft sprocket, and install them.
- In case that positions of each mating mark and each dowel pin do not fit on mating parts, make fine adjustment to the position by slightly turning camshaft(s).
- Bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins.

d. Confirm the mating marks are aligned, then finger tighten camshaft sprocket bolts. Final tightening will be done with all timing chains installed.






e. Remove stopper pins out from timing chain tensioners (secondary).






3. Install timing chain (primary) as follows:
a. Install crankshaft sprocket.
- Make sure the mating marks on crankshaft sprocket face the front of engine.






b. Install the primary timing chain.
- Water pump (G).
- Install primary timing chain so the mating mark punched (B) on camshaft sprocket is aligned with the link (A) on the timing chain, while the mating mark notched (E) on the crankshaft sprocket (D) is aligned with the link (F) on the timing chain, as shown.

Model Year 2005 - 2007 2008 - 2010
Mating mark (A) Copper link Blue link
Mating mark (F) Yellow link Copper link

- When it is difficult to align mating marks (A) with (B) and (E) with (F) of the primary timing chain with each sprocket, gradually turn the camshaft to align it with the mating marks.
- During alignment, be careful to prevent dislocation of mating mark alignments of the secondary timing chains.






4. Install internal chain guide.






- If removed, reinstall slack guide.

CAUTION:
Do not overtighten slack guide bolts. It is normal for a gap to exist under the bolt seats when bolts are tightened to specification.

- Remove stopper pin from primary timing chain tensioner.

5. Make sure again that the mating marks on camshaft sprockets and timing chain have not slipped out of alignment.
6. Tighten camshaft sprocket bolts to specification with all timing chains installed and Ring Gear Stopper Tool holding the crankshaft.

Tool number : (J-48761)


7. Install front timing chain case. Refer to EM-4, Front Timing Chain Case, Installation.

INSPECTION AFTER INSTALLATION

- Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level.
- Run engine to check for unusual noise and vibration.

NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oil/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary.






Timing Chain Tensioner






1. Internal chain guide
2. O-ring
3. Timing chain tensioner (secondary) (RH)
4. Camshaft sprocket (EXH)
5. Timing chain (secondary)
6. Timing chain (primary)
7. Camshaft sprocket RH (INT)
8. Camshaft sprocket LH (INT)
9. Slack guide
10. Timing chain tensioner (primary)
11. Crankshaft sprocket
12. Timing chain tensioner (secondary) (LH)
13. O-ring
14. Tension guide

Removal and Installation (Primary Timing Chain Tensioner)

REMOVAL

1. Remove engine room cover.
2. Remove engine under cover.
3. Partially drain engine coolant.
4. Remove lower fan shroud.
5. Disconnect crankcase ventilation hose and remove air duct and resonator assembly.
6. Disconnect MAF sensor and remove air cleaner case (upper).
7. Remove coolant reservoir hose.
8. Disconnect upper radiator hose from radiator.
9. Disconnect and remove engine cooling fan (Motor driven type).
10. Remove upper fan shroud.
11. Remove drive belt.
12. Remove drive belt auto-tensioner.
13. Remove chain tensioner cover.
14. Remove timing chain tensioner (primary) as follows:






a. Loosen clip of timing chain tensioner (primary), and release plunger stopper (1).
b. Depress plunger into tensioner body by pressing slack guide (2).
c. Keep slack guide pressed and insert stopper pin through the tensioner body hole and plunger groove (3) to hold plunger in.
- Use stopper pin included with Tool J-50246.






d. Remove timing chain tensioner bolts and remove timing chain tensioner (primary).

CAUTION:
Be careful not to drop timing chain tensioner bolts inside timing chain case.

INSTALLATION

Installation is in the reverse order of removal.
- When installing timing chain tensioner (primary), push in plunger and keep it pressed in with stopper pin.
- Remove any dirt and foreign materials completely from the back and the mounting surfaces of primary timing chain tensioner.
- After installation, pull out stopper pin.

Removal and Installation (Secondary Timing Chain Tensioner)

REMOVAL

1. Remove the timing chains (primary) and (secondary).
2. Remove the rocker covers.
3. Remove the camshaft brackets (No. 1).
4. Remove the secondary timing chain tensioners.

INSTALLATION

Installation is in the reverse order of removal.

Removal and Installation (Secondary Timing Chain Tensioner Shoe)

REMOVAL

1. Remove the timing chains (secondary). Refer to EM-9, Timing Chain.






2. Remove the secondary timing chain tensioner shoe by evenly prying at base of shoe with suitable tool as shown.

INSTALLATION






1. Install new secondary timing chain tensioner shoe using Tool (A) as shown
- Tighten the bolt until the secondary timing chain tensioner shoe is fully seated on the secondary timing chain tensioner.

CAUTION:
Do not overtighten bolt.

Tool number : (J-50246)

2. Installation of the remaining components is in the reverse order of removal.