Timing Cover: Service and Repair
FRONT TIMING CHAIN CASENOTE: This describes removal/installation procedure of front timing chain case and timing chain related parts without removing oil pan (upper) on vehicle.
When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain related parts, and rear timing chain case in this order, and install in reverse order of removal.
REMOVAL
1. Place vehicle onto lift.
2. Disconnect battery ground cable.
3. Remove engine cover with power tool.
4. Remove air cleaner case assembly.
5. Remove undercover with power tool.
6. Drain engine coolant from radiator.
7. Drain engine oil from oil pan.
8. Remove engine harnesses.
9. Remove intake manifold collector (upper) and (lower) with power tool.
10. Remove radiator cooling fan assembly.
11. Remove A/C compressor from bracket, and temporarily secure it aside.
12. Remove power steering oil pump from bracket, and temporarily secure it aside.
13. Remove power steering oil pump bracket.
14. Remove alternator.
15. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
16. Remove oil Pan (lower).
17. Remove the RH and LH intake valve timing control covers.
- Loosen bolts in reverse order as shown.
- Use seal cutter (special service tool) or an equivalent tool to cut liquid gasket for removal.
CAUTION: Shaft is internally jointed with intake camshaft sprocket center hole. When removing, keep it horizontal until it is completely disconnected.
18. Remove RH and LH rocker covers with power tool.
NOTE: When secondary timing chain is not removed/installed, this step is not required.
19. Obtain compression TDC of No.1 cylinder as follows:
NOTE: When timing chain is not removed/installed, this step is not required.
a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
b. Check that intake and exhaust cam noses on No. 1 cylinder (engine front side of RH bank) are located as shown.
If not, turn the crankshaft one revolution (360°) and align as shown.
NOTE: When only primary timing chain is removed, rocker cover does not need to be removed. To confirm that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets.
20. Remove starter motor and set ring gear stopper (special service tool) as shown.
21. Remove crankshaft pulley using a suitable puller.
CAUTION: Do not place puller directly onto crankshaft, as it may become damaged.
22. Loosen two mounting bolts in front of oil pan (upper) in reverse order shown in figure.
23. Remove front timing chain case.
a. Loosen mounting bolts in reverse order as shown.
b. Insert the appropriate size tool into the notch at the top of the front timing chain case as shown (1).
c. 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.
24. Remove water pump cover and chain tensioner cover from front timing chain case.
Use seal cutter (special service tool) or an equivalent tool to cut liquid gasket for removal.
25. Remove the front oil seal from the front timing chain case using a suitable tool.
- Use screwdriver for removal.
- Exercise care not to damage front timing chain case.
26. Remove timing chain and related parts.
27. Remove residual gasket from front timing chain case and liquid gasket mating surface.
CAUTION: Be careful not to allow gasket fragments to enter oil pan.
INSTALLATION
1. Install timing chain and related parts.
2. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
3. Install the front oil seal on the front timing chain case. Apply new engine oil to the oil seal edges.
- Install it so that each seal lip is oriented as shown in figure.
- Using a suitable drift, press-fit oil seal until it becomes flush with timing chain case end face.
- Make sure the garter spring is in position and seal lip is not inverted.
4. Install the water pump cover and the chain tensioner cover to front cover.
Apply RTV Silicone Sealant or equivalent.
5. Install front timing chain case as follows:
a. Apply liquid gasket to front timing chain case back side as shown.
Apply RTV Silicone Sealant or equivalent.
b. Install oil pan gasket.
Apply RTV Silicone Sealant or equivalent.
Align notch of front timing chain case with protrusion of oil pan gasket.
Apply liquid gasket to top surface of oil pan (upper) as shown in figure.
Use Genuine RTV Silicone Sealant or equivalent.
c. Assemble front timing chain case.
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.
CAUTION: Be careful that oil pan gasket is in place.
ii. While pressing front timing chain case from its front and top as shown in figure, install bolts and temporarily tighten them. For bolt length and positions, refer to the step 6.
iii. Hammer dowel pin until the outer end becomes flush with surface.
6. Tighten bolts to the specified torque in order shown in the figure.
8 mm (0.31 inch) dia. bolts: 1, 2
6 mm (0.24 inch) dia. bolts : Except the above
After tightening, retighten them to specified torque in numerical order shown in figure.
7. Install two mounting bolts in front of oil pan (upper) in numerical order shown in figure.
15.7 - 18.6 Nm (1.6 - 1.9 kgf-cm, 12 - 13 ft. lbs.)
8. Install RH and LH intake valve timing control covers as follows:
a. Install seal rings in shaft grooves.
b. Apply liquid gasket to the intake valve timing control covers.
Use Genuine RTV Silicone Sealant or equivalent.
c. Install collared O-ring in front cover oil hole (LH and RH sides).
d. 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 covers.
e. Tighten bolts in the numerical order as shown.
9. Install crankshaft pulley as follows:
a. Fix crankshaft using a suitable tool.
b. Install crankshaft pulley, taking care not to damage front oil seal.
When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference)
c. Tighten bolt to 39.2 to 49.0 Nm (4.0 to 5.0 kgf-cm, 29 to 36 ft. lbs.).
d. Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by 60 to 66 degrees [Target: 60 degrees (equivalent to one graduation)].
10. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
11. For the following operations, perform steps in the reverse order of removal.
NOTE: If hydraulic pressure inside chain tensioner drops after removal/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.