Removal And Installation

TIMING CHAIN

Removal and Installation


CAUTION:
- After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons.
- 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 camshaft sprockets, camshaft brackets, and crankshaft pulley.

REMOVAL

1.Remove front timing chain case. Refer to "Removal and Installation" Removal And Installation.
2.Remove the intake manifold collector. Refer to "Removal and Installation" Removal And Installation.
3.Place paint marks on the timing chain and sprockets to indicate the correct position of the components for installation.
4.Remove the timing chain tensioner (primary).





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 [1.2 mm (0.047 in)] 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 bolts and remove the timing chain tensioner.
5.Remove the internal chain guide, and slack guide.
6.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.





7.Attach a suitable stopper pin to the right and left camshaft chain tensioners (for secondary timing chains).
8.Remove timing chain (secondary) and camshaft sprockets as follows:





a.Attach a suitable stopper pin (B) to the bank 1 (A) and bank 2
(C) timing chain tensioners (secondary) (1).
NOTE:
- Use approximately 0.5 mm (0.02 in) diameter hard metal pin as a stopper pin.
- Removal of camshaft bracket (No. 1) is required prior to removing the timing chain tensioner (secondary).
b.Remove camshaft sprockets (INT and EXH) bolts.
- Apply paint to the timing chain and camshaft sprockets for alignment during installation.





- Secure the hexagonal portion of camshaft using a wrench to loosen bolts.

CAUTION:
Do not loosen bolts using anything other than the camshaft hexagonal portion. Do not apply tension to the timing chain.
c.Remove timing chain (secondary) together with camshaft sprockets.
- Turn camshaft slightly to keep the chain tight when removing the timing chain (secondary).





- Insert 0.5 mm (0.020 in) thick metal or resin plate between timing chain and timing chain tensioner plunger (guide) (E).
Remove timing chain (secondary) (2) together with camshaft sprockets with timing chain loose from guide groove.

(1) : Timing chain tensioner (secondary)
(A) : Bank 1
(B) : View B
(C) : Stopper pin
(D) : Plate
(F) : Timing chain tensioner (body)

CAUTION:
Be careful of plunger coming off when removing timing chain (secondary). The plunger of timing chain tensioner (secondary) moves during operation, which could cause the stopper pin to fall out.
- Bank 1 shown.
d.Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing chain (secondary).

CAUTION:





- Handle camshaft sprocket (INT) carefully to avoid any shock to camshaft sprocket.
- Do not disassemble. [Do not loosen bolts (A) as shown].

9.Remove the chain tension guide.

INSPECTION

Check for cracks and any excessive wear of the timing chain. Replace the timing chain as necessary.

INSTALLATION











NOTE:
The illustration shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, the components installed.
1.Install the timing chain tension guide.





2.Check that dowel pin (A) and crankshaft key (1) are located as shown. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown, for the placement of cam nose, it is generally accepted camshaft is placed in the same direction.










3.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.Install timing chain (secondary) (2) and camshaft sprockets [INT
(1) and EXH (3)].

(A) : Dowel pin groove
(B) : Mating mark (2 oblong on rear face)
(C) : Orange link
(D) : Mating mark (2 circles on rear face)
(E) : Mating mark (Oblong on rear face)
(F) : Dowel pin groove
(G) : Mating mark (Circle on rear face)
(H) : Orange link

NOTE:
Bank 1 shown (rear view).
- Align the mating marks on timing chain (secondary) (orange link) with the mating marks on camshaft sprockets (INT and
EXH), and install them.
- Align dowel pin on camshafts with the groove on sprockets, and install them.
- Tighten the bolts for the camshaft sprockets by hand enough to prevent the dowel pins from falling out of the grooves.





- 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 (A) on the top of sprocket teeth and its extended line with paint.

(B) : Mating mark (orange link)






4.After confirming the mating marks are aligned, tighten the camshaft sprocket bolts.
- Secure the camshaft using a wrench at the hexagonal portion to tighten the bolts.





5.Pull the stopper pins out from the secondary timing chain tensioners.





6.Install the crankshaft sprocket on the crankshaft.
- Make sure the mating marks on the crankshaft sprocket face the front of the engine.





7.Install the primary timing chain.
- Install primary timing chain so the mating mark (punched) (B)
on camshaft sprocket (C) is aligned with the pink link (A) on the timing chain, while the mating mark (notched) (E) on the crankshaft sprocket (D) is aligned with the orange one (F) 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.
(G): Water pump





8.Install the internal chain guide and slack guide.

CAUTION:





- Do not overtighten the slack guide bolts. It is normal for a gap to exist under the bolt seats when the bolts are tightened to specification.





9.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 materials completely from the back and the mounting surfaces of the chain tensioner.
- After installation, pull out the stopper pin while pressing the slack guide.
10.Reconfirm that the matching marks on the sprockets and the timing chain have not slipped out of alignment.
11.Install the front timing chain case. Refer to "Removal and Installation" Removal And Installation.