Timing Chain: Service and Repair
POSITION FOR APPLYING LIQUID GASKET
Before installation, wipe off any protruding sealant.
CAUTION:
^ After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons.
^ When installing camshaft, chain tensioners, oil seals, or other sliding parts, lubricate contracting surfaces with new engine oil.
^ Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets, camshaft brackets, and crankshaft pulley
^ Before disconnecting fuel hose, release fuel pressure.
^ Before removing the upper oil pan, remove the crankshaft position sensor (POS).
^ Be careful not to damage sensor edges.
^ Do not spill engine oil or coolant on drive belts.
Removal
1. Perform the Fuel Pressure Release Procedure.
2. Remove the battery.
3. Drain the engine cooling system.
4. Drain engine oil.
5. Remove engine cover with power tool.
6. Remove the intake air duct with the air cleaner case lid and mass air flow sensor.
7. Remove the engine coolant reservoir.
8. Disconnect the fuel rail quick connector at the vehicle piping side. .
9. Remove the cowl top grille and the windshield wiper assembly.
10. Remove the front RH wheel and tire with power tool.
11. Remove the engine undercovers with power tool.
12. Remove the inner fender splash shield with power tool.
13. Remove the drive belts and idler pulley.
14. Recover the A/C system R134a and remove the A/C compressor.
15. Dismount the power steering oil pump and reservoir tank. Tie them down with wire to reposition them out of the way.
16. Remove the lower end upper oil pans.
17. Remove the A/C high pressure line.
18. Remove the alternator.
19. Disconnect the engine harness and set aside.
20. Support the engine and remove the RH engine mount and bracket.
21. Remove the IVT control covers, right and left. Loosen the bolts in the numerical order as shown.
NOTE: The shaft in the cover is inserted into the center hole of the intake camshaft sprocket. Remove the cover by pulling straight out until the cover disengages from the camshafts sprocket.
22. Remove the starter motor.
23. Obtain compression TDC of No.1 cylinder as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
b. Check that intake and exhaust cam nose on No. 1 cylinder (engine front side of right) are located as shown.
If not, turn the crankshaft one revolution (360°) and align as shown.
24. Set the ring gear stopper using the mounting bolt hole.
CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting the stopper.
25. Remove the crankshaft pulley as follows:
a. Set the ring gear stopper using the mounting bolt hole.
CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear when setting the stopper.
b. Loosen crankshaft pulley mounting bolt using pulley holder and locate bolt seating surface at 10 mm (0.39 inch) from its original position.
c. Position a pulley puller at recess hole of crankshaft pulley to remove crankshaft pulley.
CAUTION: Do not use a puller claw on crankshaft pulley periphery.
26. Remove the front timing chain case.
a. Loosen the bolts in the numerical order as shown.
b. Insert the appropriate size tool into the notch (1) at the top of the front timing chain case as shown.
c. Pry off the case by moving the suitable tool (2) as shown.
^ Use seal cutter or an equivalent tool to cut liquid gasket for removal.
CAUTION:
^ Do not use a screwdriver or similar tool.
^ After removal, handle carefully so it does not bend, or warp under a load.
27. Disconnect the power brake booster vacuum hose.
28. Disconnect the electric throttle control actuator.
29. Disconnect the coolant hoses at the electric throttle control actuator.
30. Disconnect the PCV hose.
31. Disconnect the EVAP canister purge volume control solenoid vacuum hose.
32. Remove the intake manifold collector. Loosen the bolts and nuts in the numerical order as shown.
33. Remove the six ignition coils.
34. Remove the six spark plugs.
35. Remove the engine oil dipstick.
36. Remove the IVT control solenoid valves.
^ Discard the gaskets and use new gaskets for installation.
37. Remove the rocker covers. Loosen the bolts in the numerical order as shown.
38. Remove the internal chain guide.
39. Remove the timing chain tensioner and slack side chain guide.
Place paint marks on the timing chain and sprockets to indicate the correct position of the components for installation.
a. Pull lever down and release plunger stopper tab. Plunger stopper tab can be pushed up to release (coaxial structure with lever).
b. Insert stopper pin into tensioner body hole to hold lever, and keep the tab released. An Allen wrench [2.5 mm (0.098 inch)] is used for a stopper pin as an example.
c. Insert plunger into tensioner body by pressing the slack side chain guide.
d. Keep the slack side chain guide pressed and hold it by pushing the stopper pin through the lever hole and body hole.
e. Remove the mounting bolts and remove the timing chain tensioner.
40. Remove primary timing chain and crankshaft sprocket.
CAUTION: After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons.
41. Attach a suitable stopper pin to the right and left camshaft chain tensioners (for secondary timing chains)
42. Remove the intake and exhaust camshaft sprockets bolts
^ Apply paint to the timing chain and camshaft sprockets for alignment during installation.
^ Secure the hexagonal portion of the camshaft using a wrench to loosen the bolts.
43. Remove the secondary timing chains with camshaft sprockets.
a. Rotate camshaft slightly, and slacken timing chain of timing chain tensioner side.
b. Insert metal or resin plate [0.5 mm (0.020 inch)] into guide between timing chain and chain tensioner plunger. Remove cam sprocket and secondary timing chain with timing chain removed from guide groove.
CAUTION: Chain tensioner plunger can move, while stopper pin is inserted in tensioner. Plunger can come out of tensioner when timing chain is removed. Use caution during removal.
^ Intake camshaft sprocket is two-for-one structure of primary and secondary sprockets.
^ Handle the intake sprockets as an assembly.
CAUTION:
^ Avoid impact or dropping the intake sprockets.
^ Do not disassemble the intake sprockets (never loosen bolts A and B as shown).
44. Remove the chain tension guide.
45. Remove the rear timing chain case.
CAUTION:
^ Do not remove the plate metal cover for the oil passage.
^ After removing the chain case, do not apply any load to the case that might bend it.
a. Loosen and remove the rear timing chain case bolts in the order shown.
b. Cut the sealant with an appropriate tool and remove the rear timing chain case.
46. Remove O-rings to cylinder head and cylinder block.
47. Use a scraper to remove all of the old Silicone RTV Sealant from the front and rear timing chain case and opposite mating surfaces.
CAUTION: Do not damage the mating surfaces.
48. Remove all old Silicone RTV Sealant from all the bolt holes and bolts.
CAUTION: Do not damage the threads or mating surfaces.
49. Use a scraper to remove all the old Silicone RTV Sealant from the water pump cover, chain tensioner cover and IVT control covers.
CAUTION: Do not damage the mating surfaces.
50. Remove the front oil seal from the front timing chain case using a suitable tool.
CAUTION: Do not damage the front cover.
Inspection
Check for cracks and any excessive wear at the roller links of the timing chain. Replace the timing chain as necessary.
Installation
NOTE: The figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, the components installed.
1. Install rear timing chain case as follows:
a. Install O-rings on cylinder block.
b. Install O-rings on cylinder head.
2. Apply Genuine Silicone RTV Sealant or equivalent, to the rear timing chain case.
3. Align the rear timing chain case and water pump assembly with the dowel pins (RH and LH) on the cylinder block and install the case. Make sure the O-rings stay in place during installation.
a. Tighten the mounting bolts in the numerical order as shown. There are two bolt lengths used. Follow the chart for proper bolt length specifications.
b. After all bolts are initially tightened, retighten them to the specification in the numerical order as shown.
Rear timing chain case bolts: 12 - 13 Nm (1.2 - 1.4 kg-m, 9 -10 ft. lbs.)
4. Install the timing chain tension guide.
5. Position the crankshaft so No. 1 piston is set at TDC on the compression stroke.
^ Make sure that the dowel pin hole, dowel pin and crankshaft key are located as shown.
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 RH bank.
CAUTION: Hole on small diameter side must be used for intake camshaft sprocket dowel pin. Do not misidentify (ignore big diameter side).
6. Install the secondary timing chains and camshaft sprockets.
CAUTION: Matching marks between the timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process.
^ Push the sleeve of the secondary chain tensioner and keep it pressed in with a stopper pin.
a. Align the matching marks on the secondary timing chain (gold link) with the ones on the intake and exhaust sprockets (stamped), and install them.
^ Matching marks for the intake sprocket are on the back side of the secondary sprocket.
^ There are two types of matching marks, round and oval types. They should be used for the RH and LH banks, respectively.
RH bank: use round type.
LH bank: use oval type.
b. Align the dowel pin and pin hole on the camshaft with the groove and dowel pin on the sprocket, and install them.
^ On the intake side, align the pin hole on the small diameter side of the camshaft front end with the dowel pin on the back side of the camshaft sprocket, and install them.
^ On the exhaust side, align the dowel pin on the camshaft front end with the pin groove on the camshaft sprocket, and install them.
^ Mounting bolts for the camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of the 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 sprocket teeth in advance with paint.
7. After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts.
^ Secure the camshaft using a wrench at the hexagonal portion to tighten the mounting bolts.
8. Pull the stopper pins out from the secondary timing chain tensioners.
9. Install the crankshaft sprocket on the crankshaft.
^ Make sure the mating marks on the crankshaft sprocket face the front of the engine
10. Install the primary timing chain.
^ Install primary timing chain so the mating mark (punched) on camshaft sprocket is aligned with the yellow link on the timing chain. While the mating mark (notched) on the crankshaft sprocket is aligned with the orange one on the timing chain, as shown.
^ When it is difficult to align mating marks of the primary timing chain with each sprocket, gradually turn the camshaft using a wrench on the hexagonal portion to align it with the mating marks.
^ During alignment, be careful to prevent dislocation of mating mark alignments of the secondary timing chains.
11. Install the internal chain guide.
12. Install the slack guide.
^ Do not over tighten the slack guide mounting bolts. It is normal for a gap to exist under the bolt seats when the mounting bolts are tightened to specification.
13. Install the timing chain tensioner for the slack guide.
^ When installing the chain tensioner, push in the sleeve and keep it pressed in with the stopper pin.
^ Remove any dirt and foreign material completely from the back and the mounting surfaces of the chain tensioner.
^ After installation, pull out the stopper pin by pressing the slack guide.
14. Reconfirm that the matching marks on the sprockets and the timing chain have not slipped out of alignment.
15. Install new O-rings on the rear timing chain case.
16. Install the front oil seal on the front timing chain case using a suitable tool. Apply clean engine oil to the oil seal edges.
^ Install it so that each seal lip is oriented as shown.
Suitable drift
Outer diameter: 59 mm (2.32 inch)
Inner diameter: 49 mm (1.93 inch)
CAUTION: Press fit straight and avoid causing burrs or tilting the oil seal.
^ Using a suitable drift, press-fit oil seal until it becomes flush with timing chain case end face.
^ Make sure the garter spring in the oil seal is in position and seal lip is not inverted.
17. Apply Silicone RTV Sealant to front timing chain case.
^ Use Genuine Silicone RTV Sealant, or equivalent.
^ Before installation, wipe off the protruding sealant.
18. Install the rear case pin into dowel pin hole on front timing chain case.
19. Tighten bolts to the specified torque in order shown in the figure.
20. After installing the front timing chain case, check the surface height difference between the following parts on the oil pan mounting surface.
^ If not within specification, repeat the installation procedure.
Front timing chain case to rear timing chain case: (-0.14) - 0.14 mm [(-0.0055) - 0.0055 in]
Oil pump to cylinder block: (-0.36) - (-0.10) mm [(-0.0142) - (-0.0039) in]
Rear timing chain case to cylinder block: (-0.24) - 0.14 mm [(-0.0094) - 0.0055 in]
21. Install IVT control valve covers as follows:
a. Install new collared O-rings in front cover oil hole (LH and RH sides).
b. Install new seal rings on the IVT control covers.
c. Apply Silicone RTV Sealant to the IVT control covers. Use Silicone RTV Sealant, or equivalent.
^ Being careful not to move the seal ring from the installation groove, align the dowel pins on the chain case the holes to install the IVT control covers.
^ Tighten in the numerical order as shown.
22. Install the water pump cover and the chain tensioner cover. Apply Silicone RTV Sealant or equivalent.
23. Install the RH and LH rocker covers.
Rocker cover tightening procedure:
^ Tighten the rocker cover bolts in two stages in the numerical order as shown.
Stage 1: 0.96 - 2.96 Nm (0.1 - 0.3 kg-m, 9 - 26 inch lbs.)
Stage 2: 7.33 - 9.33 Nm (0.75 - 0.95 kg-m, 65 - 82 inch lbs.)
24. Install the IVT control solenoid valve bank 1 and bank 2.
IVT control solenoid valve bolts: 10 - 12 Nm (1.0 - 1.3 kg-m, 87 - 112 inch lbs.)
25. Install the engine oil dipstick.
26. Install the six spark plugs to their original positions.
Spark plugs (6): 20 - 29 Nm (2.0 - 3.0 kg-m, 14 - 22 ft. lbs.)
27. Install the six ignition coils to their original positions.
Ignition coils (6): 6.37 - 7.54 Nm (0.65 - 0.76 kg-m, 57 - 66 inch lbs.)
28. Install the intake manifold collector. Tighten the bolts and nuts in numerical order as shown.
Intake manifold collector bolts: 18 - 21 Nm (1.8 - 2.2 kg-lb, 13 - 15 ft. lbs.)
29. Connect the EVAP purge volume control solenoid hose.
30. Connect the PCV hose.
31. Connect the coolant hoses to the electric throttle control actuator.
32. Connect the power brake booster vacuum hose.
33. Connect the electric throttle control actuator harness electrical connector.
34. Install crankshaft pulley and tighten the bolt in two stages.
^ Lubricate thread and seat surface of the bolt with new engine oil.
^ Apply a paint mark for the second stage of angle tightening.
Stage 1: 39 - 49 Nm (4.0 - 5.0 kg-m, 29 - 36 ft. lbs.)
Stage 2: 60° - 65° degrees clockwise
35. Remove the ring gear stopper.
36. Install the starter motor.
37. Install the RH engine mount and bracket.
Engine mount to frame bolts (2): 66 - 74 Nm (6.7 - 7.6 kg-m, 49 - 54 ft. lbs.)
Engine mount bracket to front cover bolts (2): 79 - 90 Nm (8.0 - 9.2 kg-m, 58 - 66 ft. lbs.)
Engine mount bracket to front cover nut (1): 10 - 15 Nm (1.0 - 1.6 kg-m, 87 - 138 inch lbs.)
Engine mount to bracket nuts (2): 49 - 58 Nm (5.0 - 6.0 kg-m, 37 - 43 ft. lbs.)
38. Reposition and reconnect the engine harness.
39. Install the alternator.
40. Install the upper and lower oil pans.
41. Install the power steering pump.
42. Install the A/C compressor and recharge the system.
43. Install the idler pulley and the drive belts.
44. Install the inner fender splash shield and the engine undercovers.
45. Install the RH wheel and tire.
46. Install the windshield wiper assembly and the cowl top grille.
47. Install the fuel hose quick connector to the fuel tube at the vehicle piping side.
48. Install the engine coolant reservoir.
49. Install the intake air duct with the air cleaner case lid and mass air flow sensor.
50. Install engine cover.
51. Refill the engine with oil and coolant.
CAUTION: Wait at least 30 minutes for the Silicone RTV Sealant to set before filling the engine with fluids to avoid leaks.
52. Install the battery.
53. Activate the fuel system. Check for any leaks when the system is repressurized and correct as necessary.
54. Start the engine and check all systems for leaks or improper operation. Correct as necessary.
^ After starting engine, keep idling for three minutes. Then rev engine up to 3,000 rpm under no load to purge air from the high-pressure oil chamber of the chain tensioners. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.