Timing Cover: Service and Repair

Caution: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. Apply new engine oil to the sliding surfaces when Installing sliding parts. Sliding parts Include rocker arms, camshafts, chain tensioner, oil seal, etc. Apply new engine oil to bolt thread and seat surfaces when tightening the following: Cylinder head bolts, camshaft sprocket bolts, crankshaft pulley bolt and camshaft bracket bolts. When removing the oil pans, oil pump assembly and timing chain from engine, first remove the camshaft position sensor and the crankshaft position sensors from the assembly. Be careful not to damage sensor edges.





Removal
1. Drain engine oil.
2. Release fuel presure
3. Drain coolant by removing cylinder block drain plugs and radiator drain cock.
4. Remove left side rocker cover ornament.
5. Remove air duct to intake manifold, collector, blow-by hose, vacuum hoses, fuel hoses, wires, harness, connectors, etc.





6. Remove the following hoses: Vacuum hoses, Water hoses, Canister purge hose, Blow-by hose.





7. Remove RH and LH ignition coils.





8. Remove EGR guide tube.









9. Remove intake manifold collector supports and intake manifold collector (RH cylinder head only).





1O. Remove fuel tube assembly.





11. Remove intake manifold in reverse order of installation. See Intake Manifold in Engine Section.





12. Remove RH and LH rocker covers from cylinder head
13. Remove engine undercover.
14. Remove front RH wheel and engine side cover.
15. Remove drive belts and idler pulley bracket.





16. Remove power steering oil pump belt and power steering oil pump assembly.








17. Remove camshaft position sensor and crankshaft position sensors





18. Set No.1 piston at TDC on the compression stroke by rotating crankshaft.





19. Loosen crankshaft pulley bolt.

Note: At this time remove oil pan rear cover plate and set a suitable tool to ring gear so that crankshaft cannot rotate.





Note: Be careful not to damage the signal plate teeth.





20. Remove crankshaft pulley with a suitable puller.





21. Remove air compressor and bracket.
22. Remove front exhaust tube and its support.
23. Hang engine at right and left side engine slingers with a suitable hoist.
24. Remove right side engine mounting, mounting bracket and nuts.
25. Remove center member assembly.
26. Remove upper and lower oil pans.





27. Remove water pump cover.





28. Remove front timing chain case bolts.








29. Remove front timing chain case.





Installation
1. Apply liquid gasket to front timing chain case.





2. Install rear case pin into dowel pin hole on front timing chain case.
3. Tighten bolts to the specified torque in order shown in the image.

Note: Leave the bolts unattended for 30 minutes or more after tightening.





4. Apply liquid gasket to water pump cover.
5. Install water pump cover.





6. Apply liquid gasket to RH and LH rocker covers.





7. Install RH and LH rocker covers.

Rocker cover tightening procedure:





(a) Tighten bolts (1) to (10) in that order to 1 to 3 N.m (0.1 to 0.3 kg-m, 0.7 to 2ft-lb).
(b) Tighten bolts (1) to (10) as indicated in image to 5.4 to 7.4 N.m (0.55 to 0.75 kg-m, 47.7 to 65.1 in-lb).





8. Install intake manifold. See Intake Manifold / Service and Repair.
9. Install fuel tube assembly.





10. Install intake manifold collector gasket, with its front mark facing forwards.
11. Install intake manifold collector, supports and intake manifold collector bolt.
12. Install EGR guide tube.
13. Install RH and LH ignition coils.
14. Install rocker cover ornament on left side.





15. Install crankshaft pulley to crankshaft.
(a) Tighten to 20 to 29 N.m (2.0 to 3.0 kg-m, 14 to 22 ft-lb).
(b) Put a paint mark on the crankshaft pulley.
(c) Again tighten by turning 60° to 66°, about the angle from one hexagon bolt head corner to another.





16. Install camshaft position sensor and crankshaft position sensors.
17. Reinstall removed parts in reverse order of removal.

Note: After installing the tensioner, race the engine at about 3,000 rpm under no load to purge air from the high-pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.