Timing Cover: Service and Repair
FRONT TIMING CHAIN CASERemoval and Installation
NOTE:
^ This section 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 the reverse order of removal. Refer to "TIMING CHAIN".
^ Refer to "TIMING CHAIN" for component parts location.
REMOVAL
1. Remove engine cover with power tool. Refer to "INTAKE MANIFOLD COLLECTOR".
2. Remove undercover with power tool.
3. Release the fuel pressure. Refer to "FUEL PRESSURE RELEASE".
4. Drain engine oil. Refer to "Changing Engine Oil".
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine oil on drive belts.
5. Drain engine coolant from radiator. Refer to "Changing Engine Coolant".
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.
6. Remove radiator cooling fan assembly. Refer to "COOLING FAN".
7. Separate engine harnesses removing their brackets from front timing chain case.
8. Remove drive belts.
9. Remove power steering oil pump from bracket with piping connected, and temporarily secure it to aside. Refer to "POWER STEERING OIL PUMP".
10. Remove power steering oil pump bracket. Refer to "POWER STEERING OIL PUMP".
11. Remove alternator. Refer to "CHARGING SYSTEM".
12. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
13. Remove right and left intake valve timing control covers.
^ Loosen mounting bolts in reverse order as shown in the figure.
^ Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION: Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
14. Remove collared O-ring from front timing chain case (left and right side).
15. Remove rocker covers (right and left banks). Refer to "ROCKER COVER".
NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed.
16. Obtain No. 1 cylinder at TDC of its compression stroke 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. Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown in the figure.
^ If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed. To make sure that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets. Refer to "INSTALLATION".
17. Remove crankshaft pulley as follows:
a. Remove starter motor and set ring gear stopper [SST] as shown in the figure. Refer to "STARTING SYSTEM".
b. Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 inch) from its original position.
CAUTION: Do not remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller.
c. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through.
CAUTION: Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
18. Remove oil pan (lower). Refer to "OIL PAN AND OIL STRAINER".
19. Loosen two mounting bolts in front of oil pan (upper) in reverse order as shown in the figure.
20. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
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).
^ Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION:
^ Do not use flat-blade screwdriver or something similar.
^ After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
21. Remove O-rings from rear timing chain case.
22. Remove oil pan gasket. Refer to "OIL PAN AND OIL STRAINER".
23. Remove water pump cover and chain tensioner cover from front timing chain case.
^ Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal.
24. Remove front oil seal from front timing chain case using suitable tool.
^ Use screwdriver for removal.
CAUTION: Be careful not to damage front timing chain case.
25. Remove timing chain and related parts. Refer to "TIMING CHAIN".
26. Use scraper to remove all traces of old liquid gasket from front and rear timing chain cases and 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.
INSTALLATION
1. Install timing chain and related parts. Refer to "TIMING CHAIN".
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 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 in the figure.
^ Using suitable drift [outer diameter: 60 mm (2.36 inch)], press-fit oil seal until it becomes flush with front timing chain case end face.
^ Make sure the garter spring is in position and seal lip is not inverted.
4. Install water pump cover and chain tensioner cover to front timing chain case.
^ Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front timing chain case as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
5. Install front timing chain case as follows:
a. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000( - )] to front timing chain case back side as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
b. Install new oil pan gasket.
^ Apply liquid gasket to oil pan gasket as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
^ Align notch of front timing chain case with protrusion of oil pan gasket.
^ Apply liquid gasket with tube presser [SST: WS39930000 ( - )] to top surface of oil pan (upper) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
c. Install new O-rings on rear timing chain case.
d. 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.
CAUTION: Be careful that oil pan gasket is in place.
ii. Since front timing chain case is offset for difference of bolt holes, tight bolts temporarily with holding front timing chain case from front and top as shown in the figure.
iii. Same as the step ii, insert dowel pin with holding front timing chain case from front and top completely.
e. Tighten mounting bolts to the specified torque in numerical order as shown in the figure.
^ There are two type of mounting bolts. Refer to the following for locating bolts.
M8 bolts: 1, 2
Tightening Torque: 25.5 - 31.3 Nm (2.6 - 3.2 kg-m, 19 - 23 ft. lbs.)
M6 bolts: Except the above
Tightening Torque: 11.7 - 13.7 Nm (1.2 - 1.4 kg-m, 9 - 10 ft. lbs.)
f. After all bolts tightened, retighten them to the specified torque in numerical order as shown in the figure.
6. Install two mounting bolts in front of oil pan (upper) in numerical order as shown in the figure.
Tightening Torque: 15.7 - 18.6 Nm (1.6 - 1.9 kg-m, 12 - 13 ft. lbs.)
7. Install oil pan (lower). Refer to "OIL PAN AND OIL STRAINER".
8. 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 with tube presser [SST: WS39930000 ( - )] to intake valve timing control covers as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
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 mounting bolts in numerical order as shown in the figure.
9. Install crankshaft pulley as follows:
a. Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)].
b. 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).
c. Tighten crankshaft pulley bolt.
Tightening Torque: 39.2 - 49.0 Nm (4.0 - 5.0 kg-m, 29 - 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 65 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. Install in the reverse order of removal after this step.
NOTE: If hydraulic pressure inside timing 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.
INSPECTION AFTER INSTALLATION
^ Before starting engine, check the levels of engine coolant, lubrications and working fluid. If less than required quantity, fill to the specified level.
^ Run engine to check for unusual noise and vibration.
^ Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil and working fluid, fuel and exhaust gas.
^ Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
^ After cooling down engine, again check levels of engine coolant, engine oil and working fluid. Refill to the specified level, if necessary.
Summary of the inspection items