Timing Chain: Service and Repair
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Components
POSITION FOR APPLYING LIQUID GASKET
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- Before installation, wipe off the protruding sealant.
CAUTION:
- After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
- 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 cylinder head, camshaft sprockets, crankshaft pulley and camshaft brackets.
- Before disconnecting fuel hose, release fuel pressure.
- When removing the oil pans, oil pump assembly and timing chain from engine, first remove the crankshaft position sensor (POS) from the assembly.
Be careful not to damage sensor edges.
- Do not spill engine coolant on drive belts.
Removal
NOTE:
- This describes removal and installation procedure for front timing chain, timing-chain-related parts, and rear timing chain case when oil pan (upper) needs to be removed/installed for engine overhaul, etc.
- Refer to "FRONT TIMING CHAIN CASE" to remove and install front timing chain case, timing chain and its related parts without removing oil pan (upper).
1. Drain engine oil.
2. Drain coolant by removing cylinder block drain plugs.
3. Remove ornament cover.
4. Remove air duct to intake manifold, collector, PCV hose, vacuum hoses, fuel hoses, wires, harness, connectors and so on.
5. Remove the following.
- Water hoses
- EVAP canister purge hose
6. Remove intake manifold upper collectors loosening bolts and nuts in reverse order of tightening.
7. Remove intake manifold lower collectors loosening bolts in reverse order of tightening.
8. Remove RH and LH ignition coils.
9. Remove RH and LH intake valve timing control solenoid valves.
10. Remove RH and LH rocker covers from cylinder head.
- Loosen bolts in numerical order shown in the figure.
11. Remove engine undercover.
12. Remove front RH wheel and engine side cover.
13. Remove drive belts and idler pulley bracket.
14. Remove power steering oil pump belt and power steering oil pump assembly.
15. Remove alternator.
16. Remove crankshaft position sensor (POS).
17. Set No. 1 piston at TDC on the compression stroke by rotating crankshaft.
- Check that intake and exhaust cam nose on No. 1 cylinder are installed as shown.
If not, turn the crankshaft one revolution (360°) and align as above.
18. Loosen crankshaft pulley bolt. (At this time remove oil pan rear cover plate and set a suitable tool to ring gear so that crankshaft cannot rotate.)
- Be careful not to damage the signal plate teeth.
19. Remove crankshaft pulley with a suitable puller.
20. Remove intake valve timing control covers.
- Loosen bolts in reverse order shown in the figure.
- In the cover, the shaft is engaged with the center hole of the intake camshaft sprocket. Remove it straight out until the engagement comes off.
21. Remove air conditioner 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 front timing chain case bolts.
- Loosen bolts in reverse order shown in the figure.
28. Remove front timing chain case.
a. Insert the appropriate size tool into the notch at the top of the front timing chain case as shown (1).
b. Pry off the case by moving the tool as shown (2).
- Use seal cutter (special service tool) or an equivalent tool to cut liquid gasket for removal.
CAUTION:
- Do not use screwdrivers or something similar.
- After removal, handle it carefully so it does not tilt, cant, or warp under a load.
29. Remove water pump cover and timing chain tensioner cover from front timing chain case.
30. Remove front oil seal from front timing chain case.
31. Remove internal chain guide.
32. Remove timing chain tensioner and slack side chain guide.
- Remove chain tensioner as follows.
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 fix lever, and keep the tab released.
- In figure, Allen wrench [2.5 mm (0.098 inch)] is used for stopper pin as an example.
c) Insert plunger into tensioner body by pressing slack guide.
d) Keep slack guide pressed, and fix it by pushing stopper pin through lever hole and body hole.
e) Remove mounting bolts, and remove chain tensioner.
33. Remove primary timing chain and crankshaft sprocket.
34. Attach a suitable stopper pin to RH and LH camshaft chain tensioners. (For secondary timing chains)
35. Remove intake and exhaust camshaft sprocket bolts.
- Apply paint to timing chain and camshaft sprockets for alignment during installation.
- Secure the hexagonal portion of the camshaft using a spanner to loosen mounting bolts.
36. Remove secondary timing chains with camshaft sprockets.
a. Rotate camshaft lightly, 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 floated from guide groove.
CAUTION: Chain tensioner plunger may move, while fixed stopper pin and plunger both come off when timing chain is removed. Use caution during removal.
- Intake camshaft sprocket is two-for-one structure of primary and secondary sprockets.
- Handle intake camshaft sprocket, taking care of the following.
CAUTION:
- Avoid impact.
- Do not disassemble (Never loosen bolts A and B).
37. Remove chain tension guide and crankshaft sprocket.
38. Remove rear timing chain case as follows.
a. Loosen mounting bolts in reverse order shown in figure, and remove them.
b. Disconnect liquid gasket applied portion using seal cutter (special service tool: KV10111100) or an equivalent tool. Then remove rear timing chain case.
CAUTION:
- Do not remove plate metal cover of oil passage.
- After removing chain case, do not apply any load which affects flatness.
39. Remove RH and LH camshaft chain tensioners from cylinder head as follows.
a. Remove No. 1 camshaft brackets.
b. Remove chain tensioners with stopper pin attached.
40. 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.
41. Use a scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
Inspection
Check for cracks and excessive wear at roller links. Replace chain if necessary.
Installation
1. Install RH and LH camshaft chain tensioners to cylinder head as follows.
a. Install chain tensioners with stopper pin attached and new O-ring.
b. Install No. 1 camshaft brackets.
2. Install O-rings onto cylinder block.
3. Install O-rings to cylinder head.
4. Apply liquid gasket to rear timing chain case.
5. Align rear timing chain case and water pump assembly with dowel pins (RH and LH) on cylinder block. Then install it.
Do not allow O-ring to drop.
a. Tighten mounting bolts in order as shown in the figure.
Install two types of mounting bolts, referring to the following instructions and figure.
Bolt length: 20 mm (0.79 inch) (1, 2, 3, 6, 7, 8, 9, and 10 in the figure)
16 mm (0.63 inch) (other than the above): 12 - 13 Nm (1.2 - 1.4 kg-m, 9 - 10 ft. lbs.)
b. After all bolts are temporarily tightened, retighten them to specified torque in order shown in the figure.
6. After installing rear timing chain case, check surface height difference between following parts on oil pan mounting surface.
Standard
Rear timing chain case to cylinder block: -0.24 to 0.14 mm (-0.0094 to 0.0055 inch)
If not within standard, repeat above installation procedure.
7. Install chain tension guide.
8. Make sure that camshaft and crankshaft are at TDC position of No. 1 cylinder.
- Make sure that dowel pin hole, dowel pin and crankshaft key are located as shown in 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 RH bank
CAUTION: Hole on small diameter side must be used for intake camshaft sprocket dowel pin. Do not misidentify (Ignore big diameter side).
9. Install secondary timing chain and camshaft sprocket.
CAUTION: Matching marks between timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process.
- Push sleeve of secondary chain tensioner, and keep it pressed with stopper pin.
a. Align matching marks on secondary timing chain (gold link) with the ones on intake and exhaust sprockets (stamped). Then install them.
- Matching marks of intake sprocket are on back side of secondary sprocket.
- There are two types of matching marks: round and oval types. They should be used for RH/LH banks respectively.
RH bank: Use round type.
LH bank: Use oval type.
b. Align dowel pin and pin hole on camshaft with groove and dowel pin on sprocket. Then install them.
- On intake side, align pin hole on small diameter side of camshaft front end with dowel pin on back side of camshaft sprocket. Then install them.
- On exhaust side, align dowel pin on camshaft front end with pin groove on camshaft sprocket. Then install them.
- Mounting bolts for camshaft sprockets must be tightened in step 10. Tightening them by hand is enough to prevent 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 sprocket teeth in advance using paint.
10. After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts.
- Secure the camshaft hexagonal portion using a spanner to tighten mounting bolts.
11. Pull out the stopper pin from the secondary timing chain tensioner.
12. Install primary timing chain.
- Install crankshaft sprocket, with matching mark to timing chain facing front of engine.
- Install primary timing chain so that mating mark (punched) on camshaft sprocket is aligned with that (yellow link) on the timing chain, and mating mark (notched) on crankshaft sprocket is aligned with that on the timing chain, respectively.
- When it is difficult to align mating marks of the primary timing chain with each sprocket, gradually turn the camshaft hexagonal portion using a spanner so it is aligned with the mating mark.
13. Install internal chain guide.
14. Install slack guide.
- Take care not to overtighten mounting bolts for slack guide. It is normal for a gap to exist under bolt seats when mounting bolts are tightened to specified torque.
15. Install chain tensioner for slack guide.
- When installing chain tensioner, push in sleeve and keep it pressed with stopper pin.
- Remove dirt and foreign materials completely from back and mounting surfaces of chain tensioner.
- After installing, pull out stopper pin by pressing slack guide.
16. Confirm again that matching marks on sprockets and timing chain have not slipped.
17. Install front oil seal to front timing chain case.
18. Apply liquid gasket to water pump cover and chain tensioner cover.
- Before installation, wipe off the protruding sealant.
19. Install water pump cover and chain tensioner cover.
20. Install O-rings on rear timing chain case.
21. Apply liquid gasket to front timing chain case.
- Before installation, wipe off the protruding sealant.
22. Install front timing chain case.
- Align dowel pin on rear timing chain case with hole on front timing chain case.
23. Tighten bolts to the specified torque in order shown in the figure.
24. After installing front timing chain case, check surface height difference between following parts on oil pan mounting surface.
Standard
Front timing chain case to rear timing chain case: -0.14 to 0.14 mm (-0.0055 to 0.0055 inch)
- If not within standard, repeat above installation procedure.
25. Install intake valve timing control cover.
a. Install new O-rings at front timing chain case.
b. Install new seal ring at intake valve timing control cover with new engine oil applied on it.
c. Apply liquid gasket to intake valve timing control covers. Use genuine RTV silicone sealant or equivalent.
- Being careful not to move the seal ring from the installation groove, align the dowel pins on the chain case with the holes to install the intake valve timing control cover.
- Tighten in numerical order as shown in the figure.
26. Install RH and LH rocker covers.
Rocker cover tightening procedure:
- Tighten in numerical order as shown in the figure.
a. Tighten bolts 1 to 10 in that order to 0.96 to 2.96 Nm (0.10 to 0.30 kg-m, 9 to 26 inch lbs.).
b. Then tighten bolts 1 to 10 as indicated in figure to 7.33 to 9.33 Nm (0.75 to 0.95 kg-m, 65 to 82 inch lbs.).
27. Install RH and LH intake valve timing control solenoid valves.
28. Install RH and LH ignition coils.
29. Install intake manifold collector gasket.
30. Install intake manifold upper and lower collectors.
31. Install crankshaft pulley to crankshaft.
a. Tighten to 39.2 to 49.0 Nm (4.0 to 5.0 kg-m, 29 to 36 ft. lbs.).
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.
32. Reinstall removed parts in reverse order of removal.
- Make sure that crankshaft position sensor (POS) and heated oxygen sensor 1 (front) (bank 2) harness clamp are installed correctly as shown in figure.
- When installing fuel tube assembly.
- 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 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.