Timing Chain: Removal and Installation
Timing Chain: Removal and InstallationNOTE:
^ This information describes procedures for removing/installing front timing chain case and timing chain related parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul, etc.
REMOVAL
1) Remove engine room cover using power tool.
2) Release the fuel pressure.
3) Drain engine oil.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine oil on drive belts.
4) Drain engine coolant from radiator.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.
5) Remove radiator cooling fan assembly.
6) Separate engine harnesses removing their brackets from front timing chain case.
7) Remove drive belts.
8) Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
9) Remove power steering oil pump bracket.
10) Remove generator.
11) Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
12) Remove right and left intake valve timing control covers.
^ Loosen bolts in reverse order as shown.
^ Cut liquid gasket for removal using Tool.
Tool number KV10111100 (J-37228)
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
13) Remove collared O-rings from front timing chain case (left and right side).
14) Remove rocker covers (right and left banks).
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
15) 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 (A) (grooved line without color) with timing indicator (B).
b) Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown.
^ If not, turn crankshaft one revolution (360 degrees) and align as shown.
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.
16) Remove crankshaft pulley as follows:
a) Remove starter motor and set Tool.
Tool number (J-48761)
b) Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 in) from its original position.
CAUTION:
Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place to keep crankshaft pulley from dropping.
c) Pull crankshaft pulley with both hands to remove it.
17) Loosen two bolts in front of oil pan (upper) in reverse order as shown.
18) Remove front timing chain case as follows:
a) Loosen bolts with power tool in reverse order as shown.
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).
^ Cut liquid gasket for removal using Tool.
Tool number: KV10111100 (J- 37228)
CAUTION:
^ Do not use screwdriver or something similar.
^ After removal, handle front timing chain case carefully so it does not twist, bend, or warp under a load.
19) Remove O-rings from rear timing chain case.
20) Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
^ Cut liquid gasket for removal using Tool.
Tool number: KV10111100 (J-37228)
21) Remove front oil seal from front timing chain case using suitable tool.
CAUTION:
Be careful not to damage front timing chain case.
22) Use a 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.
23) Use a scraper to remove all traces of old liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
24) Remove timing chain tensioner (primary) as follows:
a) Loosen clip of timing chain tensioner (primary), and release plunger stopper (1).
b) Insert plunger into tensioner body by pressing slack guide (2).
c) Keep slack guide pressed and hold plunger in by pushing stopper pin through the tensioner body hole and plunger groove (3).
d) Remove bolts and remove timing chain tensioner (primary).
25 Remove internal chain guide, tension guide and slack guide.
NOTE:
Tension guide can be removed after removing timing chain (primary).
26) Remove timing chain (primary) and crankshaft sprocket.
CAUTION:
After removing timing chain (primary), do not turn crankshaft and camshaft separately, or valves will strike the piston heads.
27) Remove timing chain (secondary) and camshaft sprockets as follows:
a) Attach suitable stopper pin to the right and left timing chain tensioners (secondary).
NOTE:
^ Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin.
^For removal of timing chain tensioner (secondary), refer to [Removing camshaft bracket (No. 1) is required.]
b) Remove camshaft sprocket (INT and EXH) bolts.
^ Secure the hexagonal portion of camshaft using wrench to loosen bolts.
CAUTION:
Do not loosen bolts by securing anything other than the camshaft hexagonal portion.
c) Remove timing chain (secondary) together with camshaft sprockets.
^ Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
^ Insert 0.5 mm (0.020 in)-thick metal or resin plate between timing chain and timing chain tensioner plunger (guide). Remove timing chain (secondary) together with camshaft sprockets with timing chain loose from guide groove.
CAUTION:
Be careful of plunger coming off when removing timing chain (secondary).
NOTE:
Camshaft sprocket (INT) is a one piece integrated design sprockets for timing chain (primary) and for timing chain (secondary).
^ When handling camshaft sprocket (INT), be careful of the following:
CAUTION:
^ Handle carefully to avoid any shock to camshaft sprocket.
^ Do not disassemble. (Do not loosen bolts (A) as shown).
28) Remove water pump.
29) Remove rear timing chain case as follows:
a) Loosen and remove bolts using power tool in reverse order as shown.
b) Cut liquid gasket using Tool and remove rear timing chain case.
Tool number: KV10111100 (J-37228)
CAUTION:
^ Do not remove plate metal cover of oil passage.
^ After removal, handle rear timing chain case carefully so it does not twist, bend, or warp under a load.
30) Remove O-rings from cylinder head and camshaft bracket (No. 1).
31) Remove O-rings from cylinder block.
32) Remove timing chain tensioners (secondary) from cylinder head if necessary.
a) Remove camshaft brackets (No. 1).
b) Remove timing chain tensioners (secondary) with stopper pin attached.
33) Use scraper to remove all traces of old liquid gasket from front and rear timing chain cases, and opposite mating surfaces.
^ Remove old liquid gasket from bolt hole and thread.
34) Use scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
INSPECTION AFTER REMOVAL
Check for cracks and any excessive wear at link plates. Replace chain if necessary.
^ In the same way as for the LH bank, inspect the timing chain and associated parts on the RH bank.
INSTALLATION
NOTE:
The figure above shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.
1) Install timing chain tensioners (secondary) to cylinder head if removed.
a) Install timing chain tensioners (secondary) with stopper pin attached and new O-ring.
b) Install camshaft brackets (No. 1).
2) Install rear timing chain case as follows:
a) Install new O-rings onto cylinder block.
b) Install new O-rings to cylinder head and camshaft bracket (No. 1).
c) Apply liquid gasket using Tool to rear timing chain case back side as shown.
Use Genuine RTV Silicone Sealant or equivalent.
Tool number: WS39930000 (-)
CAUTION:
^ For (A), completely wipe off liquid gasket covering the area shown.
^ Apply liquid gasket on installation position of water pump and cylinder head very completely.
d) Align rear timing chain case with dowel pins (right and left) on cylinder block and install rear timing chain case.
^ Make sure O-rings stay in place during installation to cylinder block, cylinder head and camshaft bracket (No. 1).
e) Tighten bolts in numerical order as shown.
^ There are two type of bolts with different torque specifications.
Bolt length Bolt position Torque specification
20 mm (0.79 in) 1,2,3,6,7,8,9,10: 12.7 Nm (1.3 kg-m, 9 ft-lb)
16 mm (0.63 in) 4,5,11: 12.7 Nm (1.3 kg-m, 9 ft-lb)
16 mm (0.63 in) 12 through 26 :15.0 Nm (1.5 kg-m, 11 ft-lb)
f) After all bolts are tightened, retighten them to the specified torque in numerical order as shown.
^ If liquid gasket protrudes, wipe it off immediately.
g) After installing rear timing chain case, check the surface height difference between following parts on oil pan (upper) mounting surface.
Standard
Rear timing chain case to lower cylinder block:
-0.24 to 0.14 mm (-0.0094 to 0.0055 in)
^ If not within the standard, repeat the installation procedure.
3) Install water pump with new O-rings.
4) Make sure that dowel pin hole, dowel pin of camshaft and crankshaft key 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 for the same direction of 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 right bank.
CAUTION:
Hole on small dia. side must be used for intake side dowel pin hole. Do not mis-identify (ignore big dia. side).
5) Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION:
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions repeatedly during the installation process.
a) Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin.
b) Install timing chains (secondary) (8) and camshaft sprockets [INT (1) and EXH (9)].
^ Left bank mating marks (6)
^ Align the timing chain mating marks (secondary) (2) (blue color link) with the ones on camshaft sprockets (INT and EXH) (4), (5), (7) and (10) (punched), and install them.
NOTE:
^ Mating marks for camshaft sprocket (INT) are on the back side of camshaft sprocket (secondary).
^ There are two types of mating marks, circle (7), (10) and oval (4), (5) types. They should be used for the right and left banks, respectively.
Right bank: Use circle type (7) and (10).
Left bank: Use oval type (4) and (5)
^ Align dowel pin (3) and pin hole on camshafts with the groove (11) and dowel pin on sprockets, and install them.
^ On the intake side, align pin hole on the small diameter side of the camshaft front end with dowel pin (3) on the back side of camshaft sprocket, and install them.
^ On the exhaust side, align dowel pin on camshaft front end with pin groove (11) on camshaft sprocket, and install them.
^ In case that positions of each mating mark and each dowel pin do not fit on mating parts, make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
^ Bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the 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 top of sprocket teeth and its extended line in advance with paint.
c) After confirming the mating marks are aligned, tighten camshaft sprocket bolts.
^ Secure camshaft using wrench at the hexagonal portion to tighten bolts.
d) Pull stopper pins out from timing chain tensioners (secondary).
6) Install tension guide.
7) Install timing chain (primary) as follows:
a) Install crankshaft sprocket.
^ Make sure the mating marks on crankshaft sprocket face the front of engine.
b) Install the primary timing chain.
^ Water pump (G).
^ Install primary timing chain so the mating mark punched (B) on camshaft sprocket is aligned with the blue link (A) on the timing chain, while the mating mark notched (E) on the crankshaft sprocket (D) is aligned with the copper link (F) on the timing chain, as shown.
^ When it is difficult to align mating marks (A) with (B) and (E) with (F) 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.
8) Install internal chain guide, slack guide and timing chain tensioner (primary).
CAUTION:
Do not over tighten slack guide bolts. It is normal for a gap to exist under the bolt seats when bolts are tightened to specification.
^ When installing timing chain tensioner (primary), push in plunger and keep it pressed in with stopper pin.
^ Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary).
^ After installation, pull out stopper pin.
9) Make sure again that the mating marks on camshaft sprockets and timing chain have not slipped out of alignment.
10) Install new O-rings on rear timing chain case.
11) Install new front oil seal on 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.
^ Press-fit oil seal until it becomes flush with front timing chain case end face using suitable drift [outer diameter: 60 mm (2.36 in)].
^ Make sure the garter spring is in position and seal lip is not inverted.
12) Install water pump cover and chain tensioner cover to front timing chain case.
^ Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown.
Tool number: WS39930000 ( - )
Use Genuine RTV Silicone Sealant or equivalent.
13) Install front timing chain case as follows:
a) Apply a continuous bead of liquid gasket using Tool to front timing chain case back side as shown.
Tool number: WS39930000 ( - )
Use Genuine RTV Silicone Sealant or equivalent.
b) Install new O-rings on rear timing chain case.
c) 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.
ii) Since front timing chain case is offset for difference of bolt holes, tighten bolts temporarily while holding front timing chain case from front and top as shown.
iii) Same as the previous step, insert dowel pin while holding front timing chain case from front and top completely.
d) Tighten bolts to the specified torque in numerical order as shown.
e) After all bolts tightened, retighten them to the specified torque in numerical order as shown.
Bolt position Bolt diameter
1-5 :10 mm (0.39 in)
6-25 :6 mm (0.24 in)
Bolt position Tightening specification
1-5 :55.0 Nm (5.6 kg-m, 41 ft-lb)
6-25 :12.7 Nm (1.3 kg-m, 9 ft-lb)
14) Install two bolts in front of oil pan (upper) in numerical order as shown.
Front oil pan bolt torque :22.0 Nm (2.2 kg-m, 16 ft-lb)
15) 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 using Tool to intake valve timing control covers as shown.
Tool number: WS39930000 ( - )
Use Genuine RTV Silicone Sealant or equivalent.
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 bolts in numerical order as shown.
16) Install crankshaft pulley as follows:
a) 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).
b) Tighten crankshaft pulley bolt in two steps.
Step 1 :44.1 Nm (4.5 kg-m, 33 ft-lb)
Step 2 :84 - 90 degrees clockwise
c) Remove Tool.
Tool number (J-48761)
17) Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
18) Install oil pans (upper and lower).
19) Install rocker covers (right and left banks).
20) Installation of the remaining components is in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
^ Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
^ Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at the connection points.
^ Start engine. With engine speed increased, check again for fuel leakage at connection points.
^ Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and 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.
^ Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from passages in lines and hoses, such as in cooling system.
^ After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary.
^ Summary of the inspection items:
